Engineer Quality

**** ********** *** ***. **** Columbus, IN *****

Cell # 309-***-****, E-mail: *********@*****.***

Quality Control Engineer

Six Sigma ? Lean Manufacturing ? Continuous Product/Process Improvement ?

Project Management ?

OSHA ? CAPA ? 8D ? Statistical Analysis ? FMEA ? SPC ? Minitab ? ISO/TS

16949 ? LPA ? QCAM

SUMMARY:

7 1/2 years of experience using Quality and Lean Principles including 2 1/2

years at Cummins Inc.

6 + years of experience using Six Sigma and Lean Mfg tools.

Expertise in solving complex Design and Manufacturing problems, Root cause

analysis and implementing in-process verifications/validation.

Experienced Customer liaison- solving quality problems collaborating with

Design and Manufacturing team.

Demonstrated the abilities to perform statistical analysis and control

charts in order to resolve performance and safety related issues for diesel

and gas engines.

Expertise in implementing waste reduction tools such as 5S, VSM, 3M, 7QC,

OEE, SMED and Kaizen.

Experience in managing layered Process, Torque and Critical joint audits.

SKILL:

Quality Tools: - 5S, SMED, OEE, 3M, VSM, Minitab, 8D, PPAP, APQP, FMEA,

SPC, DOE, Pareto Analysis, Ishikawa, LPA, Internal audit

Design Software: - AutoCAD, Pro-Engineering, Teamcenter

Other: - GD&T, Microsoft Excel, Microsoft Word

Soft Skill: - Mentoring, teaching, self motivated, Problem Solving and

Analytical, Team player, Quick learner, Ability to work under pressure with

Positive attitude.

Certification:

Six Sigma Green Belt ? Continuous Product Improvement Green Belt ? Lean

Manufacturing Green Belt ? Reliability ? OSHA ? Process Change Notification

? Pro/Engineering

EXPERIENCE:

Cummins Inc. October 2011 - Present

Quality Engineer (QE)

Main role is to lead quality support to troubleshoot and reduce future

occurrences for assembly and test performance issues.

Lead Assembly and Test PQP (Plant Quality Problem) team and Interact with

support functions like materials, product engineering, Manufacturing

Engineering and SQI to reduce Plant and Test Quality Problems.

Address corrective action by using quality systems for defective material

(MNC's, CARs/PARs/SCARs, PQP, Six sigma, QCAM etc.)

Lead Root cause and permanent corrective action investigation for Customer

reported defects.

1 years of experience in leading LPA and Audit QCAM to prevent defects by

ensuring robust processes.

1 years of experience in leading Torque and Critical joint audits and

drive corrective actions to improve detection and prevent product failures.

Experience managing 4 quality techs for assembly quality and final product

audit.

Provide coverage as needed for other members of the quality team for

Customer, Custom-Fab and supplier Quality.

Completed 3 DMAIC Six-Sigma projects (1. Process improvement, 2. Design

improvement, 3. Employee training and development -contract phase)

Major plant level project worked other than six sigma - Lead effort to

reduce BIS/ELF and Engine test leak failures by statistically analyzing

manufacturing data and improving leak check process.

Perform Internal Process Quality audits, prepare QA procedures, plans, and

inspection instructions. ISO/TS 16949.

Pexco, LLC IL November 2010 - October

2011

Lean Manufacturing Engineer (KPO- Kaizen Promotion Officer)

Kaizen team leader at plant level, for conducting Kaizen Events focusing on

reducing waste in production, processes, raw materials and finished goods.

Implemented Kanban for raw material inventory that saved over 680

hours/year and reduced parts variation by 40%.

Implemented one piece flow process for Fabrication work that increased

efficiency by 20%, which equals 7000 hours/year in savings and made

material management more reasonable.

Lead Several TPM and energy savings kaizen that made work more efficient

and required less people involvement.

Caterpillar Inc, Mossville, IL April 2008 to

October 2010

Quality Control Engineer

Developed Customer Problem solving process map that helped achieving

Company's Quality Goals.

Used Oracle and SAP database to audit and improve manufacturing procedures

and products specifications based on customer requirements.

Worked as a Customer liaison with OEMs based globally to analyze Root Cause

and provide Corrective action for defects reported.

Improved productivity through combined work steps, removing non-value added

tasks (3M), adding automation (OEE), in process verifications (Poke Yoke)

and the development of effective work practices (SMED).

Developed a Product Value and Variation Metrics (PVVM) in order to Reduce

Material Cost and reduce amount of Variation in Product.

Developed the Lessons Learned Database in order to prevent Issues Carry

over in New Product Development.

Worked in a team to review Critical Customer Requirements, APQP and PPAP.

Responsible for providing Quality solution for two manufacturing plants one

based in Midwest and other in South Carolina.

Six Sigma Project - Lead the team to Identify and resolve the potential

areas in plant, which contributes major defects - (COMPLETED - as a result

reduced number of issues per month by 30%).

Six Sigma Project - Improved the Velocity to resolve Customer issues (Set

up the Process Map and identified Control Variables) - (COMPLETED and

Increased the performance by 70%).

For about a year helped team to design existing and new components of the

Diesel Engine using ProE and team center.

Emhart Glass Manufacturing Inc. Elmira, NY June 07 - October 07

Industrial Engineer (Internship during MS)

Worked on Engineering inter department Value Stream Mapping, increased the

order start on line performance by 20%.

As a part of company's Lean Manufacturing initiative worked as a team

player and successfully implemented 5S and Value stream mapping activities,

increased overall performance by 45%.

Working with management team to map an ergonomic Plant layout for new

product development, (Added space for 6 more machines).

Designing new and existing components of glass bottle scanning Machines by

using design tools like, Pro/Engineering with Wind-chill PDM (Product Data

Management) and AutoCAD.

Bharat Engineering LTD, India May 05 -July 06

Production Engineer

Used time Study and Takt time to identify the work force requirement for a

new Product.

Implemented outsourcing strategy -resulted in increased the profit by 25%.

Key player in Designing, development and manufacturing of electric panel

board (Pro/Engineering and AutoCAD)

Responsible for Planning, distributing and controlling daily production,

and provided in-process solutions for maintaining product quality.

EDUCATION:

Master of Science - Industrial and system Engineering. Aug 2006 -

February 2008

State University of New York at Buffalo, NY, USA GPA: - 3.2

B-Tech - Mechanical Engineering. July 2002 - May 2005

Maharashtra Institute of Technology, MS, INDIA GPA: - 3.84

Diploma - Mechanical Engineering. May 2000 - May 2002

B & B. Institute of Technology, GJ, INDIA

Academic Projects:

. The optimal order quantity of food products sold at Food Courts using the

Newsboy Model: Effective saving after successful project was $1383.96/7

week.

. "Industrial innovation and Innovation in Service sector" (Elmex Control

pvt. Ltd. India)

A real time study was done for a continuously growing Indian company.

These dynamic aspects involve the startup of new firm, survival, growth,

the deployment of a strategy of compensating factor differentials. Project

was discussed with PHD professor to explore the factors through which these

innovations are driven.

. Psychophysical analysis of Back Pack:

Minitab/FMEA

Used Two-Factor Factorial design to collect and analyze data and

evaluated the psychophysical effects of strap length at different weight

levels upon backpack user, and also determined optimal strap length and

optimal relationship between strap length and weight level

. Six Sigma, Quality Assurance (Using a Paper Plane)

Minitab, DMAIC

. As a final result achieved the straight length and 30 feet of distance in

each three trial.

. Performed a Gage R&R for measuring the parameters affecting the

straightness and distance of the flight

. Designed an Experiment to arrive at the factors to be controlled

. Used Response surface methodology to optimize the straightness and

distance of flight.

. Rapid Product Development of an Ergonomic Book Stand.

Pro-E, Rhino, Insight

Completed a step wise study in developing the new product right from

customer survey to real time production. Conceptual designs were developed

using 'ProE'. In order to analyze the layers 'Insight' was used. FDM 3000

was used to Rapid prototype the product using ABS plastic.

Achieved Great appraisal and first prize for the successful completion of

project.

BS THESIS:

. "HVAC Project" - Heat Load Calculation of a Multi-storey building.

. Detail study of Vapor absorption system.

Contact this candidate