Engineer Manufacturing

Rahul N Gami

**** * ********** **., ****** IL ***15

Ph: +1-309-***-**** Email: ****.*.*@*****.***, *********@*******.***

Education:

MSME, Michigan Technological University, USA (2004), GPA 3.71/4.0

BSME, Nagpur University, India (2001), GPA 3.3/4.0

Qualification and Skills:

12 year technical and leadership experience in manufacturing research and development, Additive manufacturing, Metal 3D Printing & Design, Supplier Development, Precision Electro-Chemical Machining, Autofrettage Process, Fixture design, Lean Manufacturing, Process Development, Six Sigma, PPAP, Root Cause Analysis, FMEA, GD&T, Gage R&R, SPC, Sand Casting process, Pro-E, Supply chain

Patent’s and INF’s

18 INF’s

5 Patent applications

1 Patent

Relevant Experience:

Sr. Engineer Research/Development (July ‘12 - Current)

Caterpillar, Inc., Mossville, Illinois, USA

Division: Manufacturing Technology, Production Development & Global Technology

Responsibilities:

Identify and develop new manufacturing technologies

Support new plant set-up activities (manufacturing set-up and quality system implementation)

Participate in New Product Introduction and Continuous Product/Process Improvement activities

Additive manufacturing (Design and process development)

Conduct lean manufacturing activities

Participate in new capital investment projects

Accomplishments:

Received a patent on tooling for Autofrettage process on fuel injector tips

Submitted 5 Patent applications to United States Patent Office and 18 invention notifications

Developed process for metal 3D Printing and design

Developed additive manufacturing design and process guides

Developed laser parameters for additive manufacturing process for various nickel based alloys and steels

Provided manufacturing support for CR600/1350 Engine NPI team, Low Cost Engine program and Next Gen Fuel Systems NPI team

Designed production intent tooling and developed Autofrettaged process for fuel injector and pump components to improve fatigue life and reduce/prolong cavitation damage

Developed Precision Electro Chemical Process for fuel system components

Led alternative manufacturing technologies research team for fuel system components NPI

Developed various remanufacturing processes for fuel system components

Identified and developed several new technology suppliers

Implemented two projection based assembly assist systems

Developed measurement and quality plan for a new facility

Led teams to Perform root cause analysis for critical manufacturing issues on various products

Developed processes for manufacturing turbochargers

Designed fixture to achieve 20 m flatness on thin section part using milling process

Supply Chain Engineer (June ’11 to July ‘12)

Caterpillar India Pvt. Ltd., India

Division: Manufacturing Technology, Production Development & Global Technology

Responsibilities:

Improve Casting Supplier delivery performance

Improve Supplier quality performance

Eliminate priority shipping costs

Accomplishments:

Developed part scheduling strategy

$40 Million shipping cost reduction by streamlining operations and supply chain activities

Implemented quality improvement strategy

Facilitated rapid improvement workshops (KAIZEN) at supplier facilities

Led cross functional team of design engineers, buyers, advanced manufacturing engineers and supply chain professional to improve overall efficiency of steel casting supplies

Research/Development Engineer (January ‘08 to June ‘11)

Caterpillar, Inc., Mossville, IL USA

Division: Manufacturing Technology, Production Development & Global Technology

Responsibilities:

Machining Research

Machining Technical Assistance

Perform Root Cause Analysis for manufacturing issues

Accomplishments:

Identified root causes for manufacturing quality issues on hydraulic valves and cylinders, sand casting process, motor grader under carriage assembly leakage issues and Engine block machining

Developed first robotic machining prototype in Caterpillar

Led a research team for Robotic machining of sand and metals

Led teams to optimize/improve existing manufacturing process and part quality at various Caterpillar facilities

Developed process FMEA for new and existing processes

Developed fixture design concepts for large component machining

Designed lifting devices for large component handling

Senior Consultant (March ’07 – January ‘08)

CGN & Associates, Peoria, Illinois, USA

Roles & Accomplishments:

Supplier development project, LR Nelson, (March ’07 to May ’07)

oDeveloped low cost suppliers for hose and brass fittings in India for LR Nelson industry, manufacturer of lawn sprinklers and hoses.

Design Structure and Sequencing project, CAT, Mossville (April ’07 to June ’07)

oPerformed design sequencing activity and analysis for Engine Development Group.

Supplier Development / Quality Engineer, CAT, Joliet (May ’07 – Dec. ‘07)

oImproved PPM rating for Valve and Manifold suppliers with highest PPM

oPerformed 6 Sigma activities at Supplier.

oAudited supplier for MQ12005 certification (Caterpillar supplier certification)

oPerformed Root Cause Analysis for major defects.

oDeveloped Control Plans and PFMEA’s and trained supplier for the same.

oPerformed Gage R&R activities at suppliers

oPerformed PPAP screening for new purchase finished components

Engineer (Oct. 05 – March ‘07)

Delphi Research Labs, Shelby Township, Michigan, USA

Responsibilities:

Improve manufacturing processes and address part quality

Design fixtures for critical components

Conduct workshops to train engineers on process improvement techniques

Perform root cause analysis for manufacturing issues

Accomplishments:

Performed Root Cause analysis and Corrective actions to reduce scrap rate of Steering assembly from 8% to less than 2%

Improved the functional accuracy of Fixture analysis software developed at Delphi Research Labs.

Achieved increase in productivity by refining CNC program and optimizing cutting tool geometry

Designed new cutting tools and improving product quality while machining steering and diesel engine combustion parts

Redesigned fixture to improve machined part quality and reduce scrap rate of Electronic Throttle control body

Graduate Research Assistant (Aug. 02 – Dec. 04)

Michigan Technological University, Houghton, Michigan, USA

Dissertation Topic: ‘Effect of tool geometry on tool temperature’

Responsibilities & Accomplishments:

Undertook an experimental study to find the effect of ‘Tool Geometry on Cutting Tool Temperature’

Designed CAD Models and performed FEA using IDEAS-TMG to predict temperature distribution in cutting tools with varying geometries

Design and Procurement Engineer (Aug. 01 – June 02)

TECSALES, Indore, Madhya Pradesh, INDIA

Responsibilities & Accomplishments:

Purchasing and calibration of gauges (caliper, micrometer, dial gauge, height gauge, snap gauge, plug gauge, thread gauge)

Designed special plug gauges

Trainee Engineer (Oct. 99 – Dec. 99)

Eicher Motors Ltd., Pithampur, Madhya Pradesh, INDIA

Responsibilities & Accomplishments:

Developed process sheets for machine shop

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