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Process Improvement Engineer

Raleigh, NC
April 13, 2016

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DHEERAJ KUMAR METTLA Mobile: 919-***-****

****, ******** *****, *******, **, 27606 E-Mail:


Masters of Science, Industrial Engineering, GPA: 3.24/4 (Aug ’14 - Dec ’15)

North Carolina State University, Raleigh, NC

Bachelors of Engineering, Production Engineering, GPA: 8.35/10 (Aug ’08 - Jun ’12)

Anna University, Chennai, India


Technical : Lean Six Sigma, Toyota Production Systems, PPAP, TPM, KANBAN, PDCA, Quality Auditing, Process planning, SPC, Time-Motion Study, FMEA, Process improvements, MRP, Kaizen, VSM, Engineering Documentation, CTQ, Line Balancing, Poke-Yoke, Pareto Analysis, 5S, 8D, GMP, A3, Failure Analysis, BOM, Supply Chain, Logistics, WCM, Inventory Management, TQM, BOM.

Software : SQL, PTC-Creo, Auto CAD, SOLIDWORKS, JMP, Minitab, MS-Visio, MS Access, MS Office, ARENA.


Process Improvement Engineer Intern, Interstate Resources, Georgia, USA (Jun ’15 – Aug ’15)

Productivity Improvement on Winder operations:

Conducted time and motion studies to identify value added and non-value added activities hindering production capacity.

Created value stream map to eliminate bottlenecks, improved cycle time for different paper grades and improved standards.

Enhanced the production capacity in manufacturing lines to 5.21% by implementing lean principles (DMAIC, 5S and KANBAN).

Logistics/Transportation Optimization:

Designed all process flow (MS Visio) and plant warehouse layouts by combining two into one to bring down maintenance costs.

Performed root cause Analysis (RCA) to eliminate the problems and designed a proper process flow sequences and SOP’s.

Conducted investigations in assessing manufacturing issues in transportation/logistics and generated reports for root causes.

Provided Corrective and Preventive Actions (CAPA) for atypical events and deviations within the warehouse operations.

Trained operators on new implementations plans (5S) and made in compliance with the company’s standards.

Extracted data from ERP systems and performed Pareto to identify critical factors and improved overall efficiency of logistics.

Worked with SCM- Logistics department and performed data analysis to mitigate the transportation difficulties, optimized warehouse (increased JIT capacity) and implemented a new database application system (SQL) to increase shipping rate.

Industrial Engineering Intern, Integral Coach Factory - Chennai, India (Dec ’11 - Feb ’12)

Optimized the process by reducing the cycle time and fatigue of workers and improved work standards and redesigned layouts.

Designed a new fixture using Pro-E to lessen human effort and assembly time, thereby increasing production rate and reducing manning required to assemble alternators. Also implemented 5S to reduce motion cycle time and improve work standards.

Developed a basic FMEA model identifying various failures and its severity at each step to analyze further in near future.

Increased production rate by 17.8% in GS coaches and 13.5% in AC coaches by updating the existing layouts.

Assistant Systems Engineer, Tata Consultancy Services, Chennai, India (Nov'12 - Jun'14)

Created design documents (MS-Visio) and performed Unit testing RDMS using SQL tool for Telecom Project.

Devised the strategic project plan, reviewed on monthly basis and prepared daily and weekly status reports.

Improved the efficiency (continuous improvement) of iPad application as Quality Tester. (Eco -Friendly application for airlines).

Quality Engineer Trainee, Endurance Technologies, Aurangabad, India (Dec ’10)

Attained industrial knowledge on how automotive components are ensured with high quality through QA and QC teams.

Performed process study and quality checks for high pressure casting process, collected data to work on its improvements.

Manufacturing Engineer Trainee, TI Metal Forming, Chennai, India (May ’10)

Gained shop floor experience in a production line throughout the entire value stream of the car window frames.

Inspected quality measures of manufacturing to deliver failsafe components and trained on various metal forming process.


Building Maintenance and Project Retrieval Database Management Application, NC State Facilities Department, NC

Created MS Access database application system to integrate business processes and improve the client productivity.

Utilized VBA and SQL concepts in developing algorithms to generate reports based on clients requirements on time.

Process improvement through Lean Six Sigma methodologies, Glenoit Fabrics, NC

Reduced number of defective products through process studies and DMAIC methodologies (SIPOC, RCA and Fishbone diagram).

Formulated Pareto, 5 Why’s analysis to identify defects and improved the finishing process by implementing new process flow.

Demonstrated DOE analysis and achieved an estimated savings to $13000/per year and 35% of scrap reduction.

Automated Material handling and Storage system, NCSU

Developed a prototype model for automated material handling and storage systems.

Programmed using RXlogix5000 to differentiate materials and transported to respective storage racks based on its type.

3D printing using DLP projector, Center for Additive Manufacturing and Logistics, NCSU

Built a 3D printing machine by understanding the underlying principles of additive manufacturing processes.

Forecasting and demand pattern determination, NCSU

Computed the trend and chose a best fitting trend line for a given time-series data using forecasting tools.

Determined the forecast and demand pattern using least squares method to fit the obtained trend line to the time series data.

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