Engineer Maintenance

VENU MADHAV NAGALLA

Email: *******@*****.***

Phone: 917-***-****

OBJECTIVE

To continue my career with an organization that will utilize my Management, Supervision & Administrative skills in the areas of Continuous Improvement, Lean Manufacturing, Production, Process and Material Planning to benefit mutual growth and success.

EXPERIENCE SUMMARY

Over 13+ Years of experience in Manufacturing methodologies and Plant equipment maintenance.

Currently working as a Manufacturing Engineer since October 2008 in Comefri USA which is one of the largest worldwide manufacturer of Industrial fans and Centrifugal fans in the HVAC industry.

Worked as a Plant Maintenance Engineer in Chemical Processing and Rubber processing Industries from Aug 2002 to Sep 2008.

Skilled in Lean manufacturing and CPI tools such as 5S, Kanban, Kaizen, Poke-Yoke, Cell designing, VSM, Line balancing and Standard work documents.

Knowledge of SCM, Logistics, JIT, MRP and Production Planning concepts.

7 Years of Experience in Warehouse management & Inventory control, Standard costing, Product cost analysis for sales team to Quote on new product line.

5 Years of Experience in Advanced Planning and Scheduling to Production operators to ensure On Time Deliveries.

Knowledge in Quality methodologies like QFD, SPC, DMAIC, PFMEA, Fish Bone Diagram, Flow charts and Control charts

Knowledge of ERP programs related to Manufacturing Engineering functionalities.

3 Years of experience in Designing of fixtures and Tools using AutoCAD.

Ability to read and interpret GD&T, Blue prints, Technical drawings, Schematics and Computer generated reports.

Hands on experience on CNC machines and proficient in NC programming.

Experience in plant restoration and carried typical activities like Reactors leveling, mechanical seal unit assembly, piping of various process lines, and assembly of different gearboxes.

EDUCATION

Bachelors of Technology in Mechanical Engineering

Jawaharlal Technological University, Srikalahasti, India May 2002

DME (Diploma in Mechanical Engineering)

Sri Varalakshmi Polytechnic, Machilipatnam, India April 1997

SKILLSET

Packages : Microsoft Excel, Word, Power Point, Outlook

CAD/CAM Packages : AutoCAD, AUTODESK INVENTOR, Pro-E

Internal MRP software : Galileo (Similar to SAP)

Continuous improvement : Lean, Six Sigma concepts

Quality Tools : PFMEA, Root Cause Analysis

PROFESSIONAL EXPERIENCE

Comefri USA, Hopkinsville, KY

Manufacturing Engineer Oct 2008 - Present

Planning, Scheduling & Controlling of Daily work Schedule for 60 employees and increased over all Plant efficiency by 4%.

Designed custom fans manufacturing assembly line using VSM, PFEP, JIT, 5S and Lean methods which leads to improve line productivity from 65% to 95% and reduced major customer lead time from 5 days to 3.5 days.

By using APQP & PFMEA concepts worked on a cost Reduction project of Fasteners change over in Fan assembly process and saved over $1 million over period of 5 years.

Trained over 80 shop floor operators on 5S, and conducted 5S events at every station and worked on concern organizational solutions and helped in sustaining the standards by regular audits.

Worked with the purchasing department and subcontractor, to develop lot sizes on powder coating wheels and saved freight cost of $78,000/Year and reduced subcontractor lead time by 5 days.

Effective Material planning, resource controlling and Inventory management using Galileo (ERP software) helped in improving on time deliveries from 78% to 97%.

Worked on developing Standard operating procedures (SOP) for over 40 different processes.

Conducted Time studies to calculate Takt time, Standard cycle time and Machine time and updated in the routings.

Involved in implementing Paperless Touch screen system for Lean shop floor control It manages, guides and provides visibility to status and performance of 6Ms and helped us in reducing over 2000 hrs/Year.

Actively worked on Material Organization project (5S) using PFEP, FIFO, Kanban and 5S to reduce 7 Mudas in Lean, and helped in improving productivity & Resource utilization.

Conducting cyclic physical Inventory everyday by counting of certain number of parts to identify items stock in errors.

Worked with Plant manager on Production budget included calculation of Manpower requirement determination (MRD), Overhead cost and setting KPI baselines etc.

Worked with the Quality department to implement Total Quality Lean in the plant by developing Operator checklists, SOP, Virtual Inspection Gauges at every process helped in reducing internal fan rejection by 95% and reduced the scrap rate by 75%.

Assisted Quality department in Root Cause Corrective Actions(RCCAs) & Documented 8D's for customer returns

Worked with Production supervisors to establish Daily LDMS Meetings Agenda and helped in their successful implementation.

Responsible for warehouse/inventory closure every month and submitting a report to the COO. This includes reviewing the variance in standard and medium cost.

Creating, Reviewing and modifying Bill Of Materials (BOMs) and Routings for every production item after release from Design team.

Developed a Inventory Handbook for identification of each part on the floor improved Material handlers efficiency by 30%.

Worked with the maintenance department on TPM schedule for machines

Worked with Quality department to ensure plant is ISO 9001 & ISO 14001 compliant at all times.

Member of the safety committee and conducted safety Audits every week.

Research & Investigate for new manufacturing methods and equipment.

Fenner India Ltd., Hyderabad, INDIA.

Maintenance Engineer Mar 06 - Sept 08

Worked as a Maintenance Engineer in Fenner India which Manufacturers of Drive belts, Spider Couplings, Oils seals and O-rings.

Developed a strong working knowledge of pumps, blowers, hydraulic systems and pneumatic systems.

Ensured the continuous implementation of a preventive maintenance program including the planning and coordination of major scheduled maintenance outages.

Administered the maintenance and improvement of the boiler and steam related systems.

Ensured sufficient parts, on-hand materials and manpower were available to perform work daily

Developed engineering standards, specifications, engineering practices and procedures for maintenance, repair and turnaround of plant equipments.

Determined the amount of contractors needed to work during down times in order not to exceed budget.

Supervised contractors used during special circumstances such as shutdowns.

Comply with OSHA Safety and Health rules

Sanghi Polyesters Ltd., Hyderabad, INDIA.

Maintenance Engineer Aug 02 - Feb 06

Worked as a Maintenance Engineer in Sanghi Polyesters one of the Largest Manufacturers of Polyester Yarn in India.

Lead outage maintenance projects. Wrote and reviewed maintenance procedures, initiated improvements to plant equipment and helped with troubleshooting and repair strategies. Taught classes to maintenance personnel on equipment repair.

Performed weekly equipment testing and repairs.

Responsible for specifying and ordering all parts, prepare bid specifications, engineer equipment changes, work with vendors to purchase new equipment.

Maintained Plant 5S standards in an extremely hazardous and face paced environment.

Conducted TPM events & Improved over machine setup, troubleshooting, corrective and preventive maintenance services.

Provided emergency/unscheduled and scheduled repairs of production equipment.

Read and interpreted equipment manuals and work orders to perform required maintenance and service.

Performed root-cause analysis with excellent written and oral communication skills to resolve technical problems in the equipment.

VISA STATUS: Currently on H1-B Visa

References will be duly provided upon request.

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