Engineer Injection Molding

Abhilash Reddy Buddaram Brahma

**** ********* **, *-* Ph No: 309-***-****

Peru, IL, 61354 Email:

***************@****.*******.***

Objective

To work in a dynamic and challenging environment, where I can effectively utilize my skills and experience and

hopefully gain new skills and knowledge.

Education

• Bradley University, Peoria, IL; May 2012

Masters in Manufacturing Engineering, GPA: 3.5/4.0

• Jawaharlal Nehru and Technological University, Hyderabad, INDIA; April 2008

Bachelors of Science in Mechanical Engineering, GPA: 3.6/4.0

Professional Summary

• Currently Working as Process Control Engineer at Caterpillar Inc.

• 8 Months of work experience as Manufacturing & Quality Engineer Intern at Cast Technologies

• 10 Months of work experience in Satyam BPO( India ) as Manufacturing Engineer.

• Adept in using the design software: Solid Works, AutoCAD, VisMockup, Factory-CAD

• Efficient in applying Lean Manufacturing principles, PFMEA, DOE, 8D, Kaizen, Value Stream Mapping,

TPS, SPC, DFM principle.

• Strong Knowledge In understanding and application of APQP and PPAP .

• Deep understanding of Facilities planning and Time studies concepts.

• Proficient in applying Six Sigma Principles and Tools to improve the processes.

• Proficient in NC programming, Database Management Systems: MS Access, VBA

• Strong Analytical and Trouble Shooting Skills.

Professional Experiences

Caterpillar Inc, Mossville, IL May 2012

– Present

Process Control/Supplier Quality Engineer

• Responsible for the supplier's processes from design concept to the end of product life.

• Develop current and new supplier base to follow APQP Process to improve quality and timely delivery of

parts.

• Review PPAP documentation, Process FMEA, Process Control Plans, Process Flow Diagrams, Process

Capability studies, SPC, Gage R&R Analysis and Corrective Action reports according to AIAG standards.

• Participate in 8 D analysis and lead root cause investigation actions to reduce and minimize supplier quality

defects (PPM).

• Developing suppliers with regard to root cause analysis and factual findings. Working directly with suppliers

by issuing supplier corrective action requests (SCAR). Reviewing corrective action submissions, preventive

action submissions, up to the verification of closure.

• Monitoring Supplier process changes and drive the Process Change Notification system providing

communication and getting approval of the concerned facilities..

• Handled Tier 1 Resource Outsourcing Project ensuring smooth transition of 400 parts from a single Tier 1

source to multiple Suppliers, identifying new resources and providing training In APQP and PPAP submission

process and ensuring communication between cross functional organizations.

• Facilitate communication between Cat Design Engineering, Receiving Facility Manufacturing and Suppliers

for the development of product design improvements and improve product quality.

• Conducting supplier audits and identifying repeated quality issues by supplier and maintain supplier quality

score card and recommend suppliers for qualification and /or disqualification based upon quality performance.

Cast Technologies, Peoria, IL May 2011 –

Dec 2011

Quality Engineer Intern

• Developed detailed Inspection and Work instructions on Foundry procedures.

• Developed Process FMEA and Control plans for casting and machining processes.

• Reduced customer rejections on oil pans by 20% using corrective actions and continuous improvement

projects.

• Created and maintained online Corrective Action Report system.

• Driven project to reduce internal foundry scrap rate, by collecting daily rejection data and analyzing the data

regularly and developing work instructions and corrective actions.

• Initiated and lead Six Sigma DMAIC project to reduce the Molding defect percentage from 31% to 6.5 %.

• Performed Kaizen and 5S activities.

• Conducted Internal Quality Audits as per ISO 9001 regulations.

Bradley University, Peoria, IL June 2010 - May

2011

Graduate Research Assistant

• Worked as Graduate Teaching Assistant for Process Engineering Course under Dr Ye Li, Associate Professor

IMET Department.

• Provided Research support to Dr Joseph Chen, Department Chair IMET.

• Hands on Experience on CNC Cincinnati Milacron Machine, Injection Molding, Welding, and CMM.

• Worked on Injection Molding Machines.

• Conducted Workshops to demonstrate and teach the operation of CNC Cincinnati Milacron Machines, and

Injection Molding Machines to undergraduate students in IMET department

• Supervised several High school Demonstrations held in IMET department.

Satyam BPO, Hyderabad, India.

Manufacturing Engineer May 2008 – Feb

2009

• Activities in BOM Management: Receive input from Design Engineer as EBOM (Engg bill of material)

• Prepare MBOM (Manfacturing bill of material) by using PLM tools like Team center.

• Maintain the MBOM up to date by updating the engineering changes.

• Routings Management: Prepare a machining/ assembly building sequence for a part / sales model.

• Validate the routings accurately in order to avoid discrepancies in production order releasing process.

• Preparing visual aids to better guide the operator/Assembler about safety/best practices.

Academic Projects

Advanced Technological Services, Peoria, IL Sep 2010 –

Dec 2010

Lean Manufacturing System Cell Design

• Developed detailed process at glance, Current and Future Value Stream Mapping for the process.

• Provided recommendations for improvement based on current muda (waste) within the process implementing

Lean principles

• Developed Poke-Yoke system to minimize defects

• Proposed steps to Eliminate Non Value Added Process.

• Conducted cost justification analysis of time, material and implementation of project.

• Improved the revenue by 30% by Reducing Annual Transportation cost and Overproduction Cost.

• Reduced the Lead time from 12 to 7 week days by combining two work stations there by eliminating the

waiting time and transportation time between these two stations.

Technical Skills

• Machining Processes: Cincinnati Milacron CNC machine, Injection Molding, Welding processes, Casting

Process, CMM.

• Design Software’s: AutoCAD, Master CAM, Pro E, IDEAS, and NC Programming.

• Office Tools: MS Office, MS Access, MS Project

• Statistical Packages: Mat lab, Minitab, SPC

• Database Management Systems: MS Access, VBA

• Facilities Planning: Factory Cad, Factory Flow, Team Center’s VisMocup

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