Engineering Project

S.SARAVANAKUMAR

Mobile: +91-961******* - Email ID: *********@*****.***

Professional Education:

MBA in Operation Management from ICFAI University.

B.E. in Aeronautical Engineering from Anna University. Professional Experience:

Having 8 years of Experience in Manufacturing Engineering, Industrial Engineering, Method Engineering and Production Support fields in Aerospace Industry. Industry UTC Aerospace Systems

Period Oct 2010 – Till date

Lines Airbus, Boeing, Embraer and After Market Parts Designation Senior Engineer – Manufacturing Engineering Roles and

Responsibilities

Accountable for New product Development/ Product transfers, Material Master (SAP) creation and Maintain, Bill of material creation and routing creation as per the Product Requirements, preparing the detail SOP/WI for each products, defining the process sequence of the assemblies for the production requirements and Line Balancing.

Accountable for Line Setup and Layout Design, to improve the process flow and linkage to optimize the floor space; reduce the number of work stations, Optimize the capacity and to reduce the Material flow.

Accountable for Cell design, Kaizen, Value stream Mapping (VSM), Line Balancing, 3P, RRCA, and new creative projects which would supports to improve the productivity as well as cost saving.

Knowledgeable in Lean concepts and tools with a passion for implementing in the practical application. Applied six lean guidelines principles, and Pull system in the VSM event and implemented the single piece flow concepts in Airbus and Boeing lines.

Developed FMS (Flexible Manufacturing System) line by Combining the A330 and A340 lines, through with the Mixed line Concept was successfully implemented and consistently meeting the Customer Takt.

Accountable for Airbus cell, line back logistic. Responsible to reduce the inventory store space by enhance the supplier performance, which would support to utilize the excess space for future new product.

Responsible to design and develop innovative Tools, fixtures and Machines (Automation) for the process which would supports to reduce the set up time and also enrich the quality of the product.

Supporting the Daily Production by providing resolutions on time to reduce the Delay in the Process Time, in meeting the Customer Delivery On-time.

Implemented Level 1 Mistake Proof for the Airbus (Longrange) Product Line by resolved the Dimension dispute, which was Persistence for last 6 years.

Responsible to Complete the First Article Inspection’s (AS9100C Standard) for the New Products also need to get Approval from internal Quality team and Customer. SKILL SETS

Coordinator of Configuration Management and manufacturing releases of Engineering Change Notifications (ECN) and implementation of Engineering Change orders (ECO) in the Shop floor Effectively, Consistently achieving Zero NC’s in the last 5 years BSI Audit.

Responsible for technical training to all operators with respect to Product requirements to improve the Skill Matrix.

Responsible in Creating and Developing the Manufacturing Standard Work Instructions for the Airbus and Boeing product lines which contains process and product information’s, tools information’s and explanation about the knowledge’s of the products.

Coordinator for the Execution and Implementation of EHS (Environmental Health and Safety) policy, Job Hazard Analysis (JHA) and Laceration Prevention Program.

Generating and analysing the DTM report, resulted in reduction of the product lead time and improvement in Operator efficiency.

Knowledge in Different types of Manufacturing Process, SAP, Engineering Drawing and CCB Process.

Knowledge in Lean Transformation and Flow Disruption Management.

Knowledge in Lean tools like Takt, Poka-Yoke, Production Preparation Process (3P), VSM.

Knowledge in Project Management and Machine Guarding.

Knowledge in UTC Aerospace FAI Process.

Knowledge in GD&T.

Industry Capgemini Consulting India Pvt. Ltd

Period Mar 2008 – Oct 2010

Line Bombardier Aerospace

Designation Product Support Engineer

Roles and

Responsibilities

Responsible in Maintaining Manufacturing data in SAP (MM): Create, Change and maintain the Bill of material of the products.

Analysed the Bombardier Aerospace Engineering drawings and documentation for materials

(BOM), and Quality elements.

Creating and Updating the Aircraft Illustrated Parts Catalogue, Aircraft Maintenance Manuals, Component Maintenance Manuals and Illustrated Tools and Equipment Manual to incorporate the details of Minor Change Leaflets, Engineering Change Requests, Repair Schemes, Temporary Revisions, Service Newsletters, and Service Bulletins.

Creation of Technical Manuals (AIPC, AMM, CMM and ITEM), Descriptive and Procedural Data Modules for Commercial Aircraft using ATA 100, ATA iSpec 2200, SAP, Arbor text Epic Editor, Adobe Frame Maker, and ASD-STE100 (Simplified Technical English). Professional Accomplishments:

1.Project Title Air cure time reduction for Airbus (LR) Role Leader

Summary

Successfully implemented the primary and secondary air cure time reduction in to the production. It helped to Reduce 18 hrs curing time of. Per unit in total Days to Manufacture (DTM) of each unit. It supported to save 15120 Hours per Annum by which team can manufacture approx. 97 additional inflatables / annum which will increase the profit by $83518 to the organization. Tools Used Line Balancing, Set-up time, DIVE.

2.Project Title Fabric Yield Improvement for Airbus (LR) Role Leader

Summary Optimized the utilization of Raw Material for Airbus (LR) and A380 lines, which supported to yield savings of 6 Sq-ft per unit, achieved savings of $142560 per annum. Tools Used Lean Tools, Set-up time.

3.Project Title Elimination of Masking tape (Hazardous Waste) for Airbus and Boeing Lines Role Leader

Summary Implemented the free hand painting methodology in Airbus380, Boeing and Embraer product lines which helped to eliminate the use of Masking tape. The Potential Cost Saving is: $116529 / Annum. In addition, it helped to eliminate the Regulated waste Disposal of 4080 kg/Annum which were sent for incineration of hazardous waste and Saved Standard Hours of 7440 hours / annum. Tools Used Lean Tools, Set-up time, RRCA, 5Why

4.Project Title Implement the New Technology in to Joining Process for Boeing737 line Role Implementation leader

Summary Implemented the New Heat Seal technology joining process which has enhanced from the conventional Joining process for the inflatables (Emergency Door). The Potential savings are reduction in Manpower of 8, DTM of 1 day and 33% of adhesive application usage. Tools Used Lean Guidelines, Single Piece flow, Pull system, FIFO, Line Balancing, 3P, and Kaizen 5.Project Title New Product transfer – MRJ

Role Leader

Summary Played lead role in the development and fabrication of the first FAI Mitsubishi Regional Jet (MRJ) Inflatable. The inflatable has been built and shipped to customer and the unit was successfully passed the final deployment test at the customer plant. This was a landmark achievement is helping to acquire market for the new product for EVACS.

Tools Used Passport Process, Cell design, Layout, Line set-up, 3P, SAP (BOM & Routing), SJI 6.Event Value Stream Mapping (VSM)

Summary Lead the Value Stream Mapping event for B737 line and reduces the DTM (Days to Manufacture) from 6.1 to 3.5 days by standardised the process flow, level loaded the operator effort. 7.Event MSW & Cell Design Event

Summary Conducted MSW & CD event in joining process for Airbus and Boeing line which supported to enhance the productivity by 20 % and reduced the standard hours by 10.34 % per unit. The potential savings through this event was $95000 / Annum

8.Event E-Kanban Methodology

Summary Applied fishbone technique to Implement E-Kanban Methodology (Supermarket) in Boeing/Airbus lines which supported to streamline the process flow and retains the safety stock to run the production in uncertain circumstances. Additionally, this process implementation helps to reduce the DTM and eradicated the wait time of 5 hours in sub assembly and 14 hours in Joining process. 9.Event Kaizen events

Summary Material Optimization and implemented single piece flow for Airbus (LR) subassembly process and Bonding process. Achieved savings of $26800 per annum through this event. Rewards and Recognitions:

Awards Received ACE/CI Event of the Quarter Award at UTC Aerospace Systems for Productivity enhancement and reduced the DTM.

Received Project of the Quarter Award for Air Cure time reduction Project at UTC Aerospace Systems for reduced the curing time and enhances the DTM of Airbus Long-range inflatable.

Received a Spot Award in the Last Quarter of 2015 at UTC Aerospace Systems for implementation of free hand paint for Airbus 380, Boeing and Embraer product lines.

Received a Spot Award in the First quarter of 2016 at UTC Aerospace Systems for developed and implemented the single piece flow and E-Kanban Methodology.

Received a Spot Award in the First quarter of 2016 at UTC Aerospace Systems for reduced the hazardous waste by implementing the free hand painting process change

Received Spot Award for the second quarter of 2011 at UTC Aerospace Systems for developing the standard operating procedure for Airbus Long-range product.

Received a Productivity & Quality award (PQA) for the third quarter of 2009 at Cap Gemini. Trainings and Certifications:

Accomplished Project in “Design and Fabrication of a Scramjet Combustor Model for Flow Visualization Studies using a Schlieren Technique” at National Aerospace Laboratories (NAL- Bangalore).

Attended Flight Training at IIT, Kanpur.

Attended Training on Lean and Process Engineering at UTC.

Attended Training on Manufacturing Standard Work and Cell Design at UTC.

Attended Training on Six Sigma and DMAIC Methodology at Capgemini. PERSONAL PROFILE:

Date of Birth 1st January 1986

Sex Male

Marital status Single

Nationality Indian

Address 182/4, Ramesh Nagar, Marathahalli Bangalore-37 Languages English, Tamil and Kannada

Passport # N5909254

I hereby declare that the above-furnished details are true to the best of my knowledge. Date: S.SARAVANAKUMAR

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