Vision-driven, analytical Senior Product Support / Quality Assurance Engineer with a wealth of success in leading world class quality assurance and development initiatives for globally renowned automotive and heavy equipment companies. Proven lean manufacturing professional who excels as a pivotal business partner and provides critical strategic leadership to internal clients and the management team. Demonstrated ability to learn and teach new concepts, easily adapt to change and manage multiple concurrent tasks. Innovative professional with excellent organizational and communication skills, and proven track record of success.

Quality Improvement Solution Engineering Project Management Efficiency Improvement

Business Process Analysis Lean Manufacturing Six Sigma Methodologies Process Improvement

Statistical Analysis ISO-9000 Cross-functional Leadership Quality Assurance

Career History

CATERPILLAR (THROUGH INFOTREE SERVICE INC.)

Product Engineer Jun 2014 - Present

Lead design collaboration for light fabrications and enclosures (sheet metal & nonmetallic) to assure requirements are met for the North American market.

Evaluates, defines, and resolves design and manufacturing problems for enclosures (sheet metal & nonmetallic) and CAB components.

Support Concurrent Product & Process Development (CPPD) with HEDC/Japan, Suppliers, Global Purchasing, and Manufacturing.

Support New Product Introduction (NPI), Advanced Quality Product Planning (APQP), Continuous Product Improvement (CPI), engineering changes, quality deviations, and cost management.

Provide technical support to CAT Victoria manufacturing facility for the Hydraulic Excavators.

Works with manufacturability teams resolving problems with manufacturing and statistical process controls

Prepares concept, design, and development and feasibility studies of complex engineering projects

Uses technical expertise and product knowledge to play the leadership role in the problem resolution process when interfacing with Test and Evaluation, Service, Plant personnel, suppliers and consultants

Coordinates product test with proven design and prototype build up and test areas

Travels to foreign and domestic plants, dealerships, suppliers and customer job sites to solve design problems or to field-test locations to evaluate a product improvement

Collaborate with internal and external customers on technical requirements

Meet cost targets established by local NPI team and cost management office

Engineered Plastic Components

Quality Engineer Dec-2013 thru Mar-2014

Acted as a single point of contact for customers regarding quality.

As a Customer Quality Engineer works together with the customers to understand quality performance, issues and drives improvements throughout the organization.

Ensures regular communication to key customers. Both reactive (complaint progress report) and proactive

Leads complaint handling process, ensures fast response on complaints, makes sure communication is done fast and good, minimizing impact to customer.

Coordinate and maintain PPAP documentation, interface with customers as required

Conducts inspection and testing of prototype/samples and records data (dimensional layout), assists in the development of Control Plans, Process Flow, Characteristic Matrix, Warrants, etc. as directed by the Quality Manager.

Provides information from drawings or samples or specifications in order to enable machines to be set up to run parts checks first piece samples using manual, electronic, and computerized testing equipment, verifies production or alerts Managers/Lead Hands to problems.

Perform process improvement tools like root cause analysis techniques, 7-discipline / 8- D report and Fishbone diagrams.

Coordinate with the production team to develop/implement process changes by updating Process flow charts, PFMEA’s & Control plans

Interface regularly with customers, dealt with complaints tactfully and provided corrective/preventive actions on part defects like non-fills, out of specification dimensions etc.

Supervise quality inspections, plotted results on pareto charts to monitor pattern of PPM

CATERPILLAR

Quality Engineer 2008-2013

Acted as Primary Contact for large mining truck shop floor quality issues.

Executed timely LMT Prime Product Rework process (PPR) to maximize ship time while minimizing quality issues.

Analyzed field issues within the first 200 hours, investigated issues, lead or assigned to proper functional area.

Identified and prioritized product issues to be solved with CPS and Six Sigma methodologies.

Participated in root cause analysis (RCA) and voice of customer (VOC) processes for the large mining truck group.

Established root cause analysis and lead CPI projects.

Participated in APQP teams to support new product launches.

Participated in the Process Failure Mode and Effect Analysis (PFMEA) activities

Shepherded the coordination of internal quality audits; pre-delivery inspection and quality gate check audit.

Participates in projects (R&D) and makes sure that customer requirements are translated into specifications and robust processes in operations

Scrutinized and validated filed research and testing data for impending operational issues and performance linkages.

Instituted Monthly DPU metrics for all plant mining products.

Utilized management tools, graphs and reports to generate, interpret, analyze and communicate results.

Authored comprehensive reports for presentation to senior leadership.

CATERPILLAR (THROUGH VOLT TECHNICAL RESOURCES)

Quality Engineer 2005-2008

Partnered with internal teammates to attain CQMS certification for various machining sections.

Identified special characteristics, Control Plan, Flow Diagram and PFMEA.

Ensured PFMEA, Control Plans, Instruction Instructions and more are kept up-to-date by developing and managing the impact system.

Steered all machining sections to Gold certification.

Initiated corrective action based on SPC data and guaranteed timely remedies.

Maintained X bar-R bar charts to monitor process parameters.

Offered expert advice on document enhancement and retention.

Oversaw the maintenance of ISO documentation and controls, administered activities necessary to maintain ISO certification and provided training to maintain ISO system.

Pinpointed PPAP requirement per AIAG PPAP manual and plant quality procedure.

Drove Six Sigma Green Belt quality improvement projects.

Minimized variation in manufacturing cells.

Conceptualized and implemented process controls, SPC, DOE and quality problem solving solutions in the manufacturing process.

Led the inspection and testing of prototypes and samples and recorded test data.

Assisted with the creation of Control Plans, Process Flow, Characteristic Matrix and Warrants.

Education & Training

Master of Science in Mechanical Engineering, Wayne State University, Detroit, Michigan

Bachelor of Science in Mechanical Engineering, N.E.D. Engineering University, Karachi, Pakistan

Six Sigma Green Belt

APQP How-To Workshop – AIAG Detroit

Project Management – YCA

Special Characteristics Training

FMEA Workshop

MSHA Mine Safety – New Miner Surface Training

Experience with CAT Engineering Standards, HVC and 1E Specs

Technical Skills

Platforms: Unix, Windows NT, Lotus Notes

Tools: Pro-Engineering / Creo, Teamcenter, AutoCAD 2000, Solidworks 2000, Minitab 15,

MS Office Suite

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