Mechanical Engineer Quality

HIMABINDU BODDUNA

Email: ********@*****.*** MOBILE: 443-***-****

SUMMARY:

Won the “Presidents Quality Award” - 2012 in Caterpillar Inc. as Reliability/Quality Engineer

4+ Years of experience in Product Quality management, Mechanical Design and Analysis

Experienced in Reliability, APQP and Product Improvement with 2+ years of experience in Automotive industry

Certified Six Sigma DMAIC & DMEDI Green belt from Caterpillar Inc.

Strong knowledge and experience in APQP, PPAP, GD&T & AIAG standards,

Facilitated/Participated in FMEA development for New content and special characteristics

Experience in Statistical Process control (SPC), Developed and Analyzed the Control Plans

Experience in Warranty data analysis, Failure mode - Root cause analysis, Carryover analysis and remarkable in Report creation

Working knowledge towards AutoCAD, Pro-E, ABAQUS, IDEAS-12 and ANSYS

Experience in Thermal, Fluid, Static and Dynamic Stress FEA analysis

Proficient in MS-Office applications. Highly knowledgeable in Excel Macro development

Familiar with “Design for Manufacturability and Assembly”(DFMA) & “Design for Serviceability”

Experience in creating “Standard Operating Procedures” (SOP)

Nominated for “Chairman’s Award” – 2012 in Caterpillar Inc.

Can handle multiple assignments simultaneously with exceeding overlapping deadlines

Awarded as “Outstanding Student” for year 2008 in University of Missouri – Kansas city

Published a paper on “Finite Element Modeling of Human Knee in Computational Environment

SKILLS:

Quality Management : Six SIGMA, GD&T, APQP, Proactive Reliability, PPAP, DMAIC, DMEDI, FMEA, Control Plan

Design & Analysis : AutoCAD, Solid Works, Pro-E, ABAQUS, IDEAS-12, ANSYS, True Grid

Computer Applications : MS Word, Excel, PowerPoint, Visio 2003 & 2007,

Other : MATLAB/Simulink, Slicer, Geomagic Studio

EDUCATION:

Master of Science - Mechanical Engineer, GPA - 3.9/4.0

University of Missouri – Kansas City, MO

WORK EXPERIENCE:

Role: Reliability/ Quality Engineer

CATERPILLAR INC. Decatur, IL April 2010 – Sep 2012

Project: Proactive Reliability/ Quality for New and Current Productions (NPI & CPI)

Proactive Reliability (PR) is a methodology to deliver the Quality product on Time, while optimizing costs by coordinating multiple groups to proactively minimize the risk. It involves FMEA development, early stage Risk identification and optimal Validation Plan creation with the use of APQP.

Responsibilities:

Collaboratively work with Design, Validation & Manufacturing groups to successfully implement Proactive Reliability throughout NPI & CPI

Facilitate the FMEA development. Review all Critical Customer Requirements (CCR) covered with FMEA

Collect/Analyze the Warranty failure data; perform Root Cause Failure Analysis

Develop mDRF Trend Analysis report, Reliability Target and Current performance reports

Maintain the FMEA’s, update DVP&R with status of Prevention, Detection validation activities and Recommended Actions

Summarize Quality data; generate reports for more than 30 NPI programs in Caterpillar Inc.

Role: Mechanical Engineer

CAPRICORN PHARMA, Frederick, MD AUG 2009 – NOV 2009

Capricorn Pharmaceuticals is a drug manufacturing facility where precision over quality manufacturing environment is extremely important

Responsibilities:

Perform daily Quality checks on manufacturing machines before each manufacturing operation

Assure the proper performance of HVAC and water systems to maintain highest quality during drug manufacturing

Observe/Control the Pressure and Humidity variations in manufacturing areas

Introduce New machines, perform Installation and Operational qualification tests before incorporating the machines to product line

Prepare Standard Operating Procedures (SOP) for the new machines introduced

a.Hot Melt Glue Machine was introduced to increase the capability of carton packaging with this automated packaging system

b.Vertical Form, Fill and Seal packaging machine was introduced to pack the sachets and tubes for free flowing drug

c.Induction sealer was introduced to seal the bottle caps with air tight sealing after tablets were filled

Role: Reliability/Quality Engineer

CATERPILLAR INC. Peoria, IL July 2008 – Mar 2009

Project: Advanced Product Quality Planning (APQP) for Caterpillar Engines

The project APQP for New Product Line has started to increase the Product Quality with structured methodology of Product manufacturing from planning to production. APQP helps to organize production processes, identifying the required changes in early stages and reduce the production timeline and cost with proper planning. The other benefits include, reduce the complexity of product development, proper identification of customer requirements, proper communication b/w supply chain and customers.

Responsibilities:

Conducted the Current Product reliability studies to estimate New Product Reliability

Obtained product quality by applying APQP and PPAP to New Product Line of CATERPILLAR engines

Maintained Proper communication with customer to clearly understand their needs regarding the product reliability and product submission deadlines

Developed Time-frame for Design Reviews and conducted the Design Reviews

Documented all specification necessary for New Product Line (NPI)

Developed and documented the Process Flow charts

Documented “Special Product and Process Characteristics” and developed the Characteristics matrix

Developed documents related to DFMEA (Design Failure Mode and Effects Analysis) & PFMEA (Process Failure mode and Effects Analysis)

Developed prototype, pre-launch control plans and documented the packaging standards.

Project: Reliability of Current Product and New Product

The main objective of the project is to calculate the Reliability on Current products and New Products. The reliability calculations help to deliver a quality product by finding the failures at early stages and by keeping track of them

Responsibilities:

Calculated Reliability for Tier2 & Tier3 Caterpillar Engines

Prepared Failure reports including population count and Warranty reports

Analyzed the failure data based on part numbers, sales models, quarterly failures, process or supplier related failures etc.

Calculated the Failure rate for particular model with the help of Weibull Plots

Prepared DRF histograms to observe the DRF trend and to address severe failure modes

Analyzed the failure data to validate the need for a CPI project. Recorded Severity of FM, Effected population, Frequency of failures etc.

Performed Failure Mode & Root cause analysis, propose the Corrective actions

Estimated Reliability of New product model based on predecessor models reliability.

Performed the Carryover analysis for New product Introduction (NPI)

Role: Design Engineer / Research Assistant

UNIVERSITY OF MISSOURI, Kansas City, MO Aug 2006 - July 2008

Project: Finite Element (FE) Modeling of Human Knee

Developing Finite element model of Human knee is very complicated due to geometry and curvature of human parts. This project included the 3D modeling of Human knee and performs FEA analysis using ABAQUS

Responsibilities:

Collected the 2D images of human knee by utilizing Magnetic Resonance Imaging (MRI) technique

Refined the image data by 75% by correcting the discontinuities and removing the noise using software Slicer and Geomagic Studio

Developed 3D model of human knee using the CAD software.

Developed the meshing of knee model with hexahedral elements using the software TRUEGRID

Developed an accurate finite element model based on various boundary conditions in ABAQUS

Analyzed the static & dynamic stress-strain vs. force relationships for the FE model

Role: Mechanical Engineer

CENTRAL INSTITUTE OF TOOL DESIGN, Hyderabad, India May 2004 - May 2005

Project: Deburring of Castings using Low Cost Automation

The main objective of the project is to develop the “Burr removal process of Castings” using the Low Cost Automation. The proposed Low cost automation technique uses the conventional method of brushes for Deburring of Castings but with the automated process by using PLC and Pneumatics

Responsibilities:

Changed the Manual process of Deburring to Automation in the company.

Applied the automation technique to the Deburring operations of castings with the use of pneumatics and PLC.

Developed an operational sequence for Deburring process to run on the PLC programming

Developed the cost analysis for both manual and automated methods to test the feasibility of automation.

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