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Project Engineer/ Six Sigma Black Belt/ Lean Manufacturing Black Belt

Peoria, Illinois, United States
October 12, 2016

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Xiumei (Ruth) Zhao


***** * ********** **, ******, IL, 61525


Six Sigma Black Belt

*-***** ******* ********** ** engineering and CPI (Continuous Product Improvement) in U.S.

8-years working experience in engineering and NPI(New Product Introduction) in Caterpillar Qinzhou

Proven success in delivering complex NPI,CPI projects on cost, on quality and on time

Deep expertise and understanding customers’ needs in different market segments (Lifecycle Performance, Lifecycle Value, Utility)

Excellent in planning, organization and project management skills; passionate, persevering and willing to brainstorm ways to achieve best solution

Deep expertise in product development processes, lean Manufacturing and Caterpillar systems, such as CPI, NPI, Teamcenter, DCC, etc.

Excellent skills using PROE/CREO/Solidwork, AutoCAD, Microsoft Project, CPLEX


Bradley University, East Peoria, IL

Graduate Teaching and Research Assistant 2015.9 – Present

Caterpillar, East Peoria, IL

6 Sigma Black Belt,MTP Product Suport and Parts 2012.10 – 2015.9

Led project teams from Peoria, Brazil, Thailand and Japan to improve Tractor’s quality and reliability in order to improve customer’s satisfaction and meet customer’s needs with a sense of urgency.

Led Cross-functional team solving 17 CPI Projects which saved $2M warranty cost; Average days to complete a project in less one year which helped the organization to achieve the target to improve average Days to Close on projects to 360 days.

Led the team quickly and effectively solving customer problems.

Coached team members in Six Sigma Methodology, Design of Experiment, and Pugh Matrix which helped team using a logical, systematic and data driven approach to solve problems.

Planed, deployed and led all project activities that would identify improvement opportunities to improve the product quality and reliability.

Created and communicated project reports to management and provided the visibility of the project status.

Completed Master Black Training at Caterpillar

Caterpillar,Aurora, IL

6 Sigma Black Belt,Midem Wheel Loader Continuous Product Improvement (CPI) 2010.08– 2012.10

Led project teams from Aurora, Brazil, Japan and China to improve wheel loader’s quality and reliability in order to improve customer’s satisfaction and meet customer’s needs with a sense of urgency.

Led Cross-functional team worldwide resolving 7 CPI Projects which improved reliability and durability of Medium Wheel Loaders built in US, Brazil, Japan and China.

Fixed Rear Clamshell Hood Panel Cracked issues on 966K/972K/980K wheel loaders,saved warranty cost $3000 per unit

Resolved cooling Hose leaking issue on 966K/972K wheel loaders,improved the failure rate from 4.27% to 0.7%;

Delivered 980H MWL fan motor hose oil leaking issue in 6months through data analysis, engaged in design engineer, service engineer, subject expertise and suppliers.

Conducted MGPP plan to help improve hardware rusting issues on 966/972/980 wheel loaders

Coached CPI Black Belts from China facilities with the CPI tools and process.

Caterpillar Qingzhou, China

New Product Introduction (NPI) Machine Integration Technical Team Leader 2007 –2010

Responsible to deliver NPI programs to meet cost, quality and timeliness target per the NPI dashboard; Lead multi-functional team and manage all phases of the NPI process for Wheel Loaders

Led a technical team at Caterpillar Qingzhou to deliver 1st generation of 616B wheel loader from launch to production in 18 Months. The project result achieved best quality and reliability in domestic marketing, meanwhile the machine variable margin was improved from 10% to 20%.

Led multi-functional team to design and launch the 652B into production following the NPI process in 24 months; met the challenging cost target and improved the fuel efficiency which saved customer 30,000RMB per year.

Demonstrated highly effective organizational, team integration, cost and time management, and leadership skills. Very focused on delivering exceptional results to all internal and external customers.

Shandong SEM Machinery Co., Ltd, China

Design Engineer / Project leader/Cost Management 2002-2007

Developed and implemented the new design of structures and work tools of GenI and GenII wheel loaders. Led the projects to improve the quality and reliability of ZL16, 30, 50, 60 wheel loaders as well as reduce the cost of the product by optimizing the design and introducing better supplier.

Completed 10 cost reduction projects and realized profit about 5M RMB annually; For Example, optimizing the design of the parts to improve the material usage from 70% to 85%.

Developed diversity products to help company improve the marketing pins and profits. For Example, developing various work tools, large structure components to match customer’s applications.

Completed various CPI projects to improve the machine reliability. For example, Improved the use life of bucket teeth/Bucket wear plate from 500H to 1500H, which reduced the warranty cost by 30%.

Initiated ZL30/40/50/60 wheel loader hardware commonality project and documented $1.7M in cost savings by eliminating 141 parts and replacing 27 Non-Preferred to Preferred Parts.


M.S, Manufacturing Engineering Expected graduate: December 2016

Bradley University

B.S., Mechanical Engineering

Taiyuan University of Science & Technology Shanxi, China


6 Sigma Master Black Belt

6 Sigma Black Belt

Patent NO: ZL20102 0599 122.4 Name: Quick Coupler Assembly

Publications: Development of a Six Sigma framework minimizing quality defects in 3D Printing Process

Presented in International Conference on Technology Management (ICTM 2016) in Chicago, USA

Interviewed by Caterpillar's Women's Initiatives Network as a young female engineering leader

Toaster master Competent Communicator (CC) Award

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