Sai Krishna Sama

***** **** **** *****, ********** Hills, MI- 48335 acycon@r.postjobfree.com 315-***-****

EDUCATION

Syracuse University May 2016

Masters in Mechanical Engineering

Jawaharlal Nehru Technological University May 2014

Bachelor of Mechanical Engineering

PROFESSIONAL EXPERIENCE

Quality Engineer (Design), Mahindra & Mahindra Ltd, Hyderabad, India Nov 2013- June 2014

Used Solidworks 3D CAD modeling software for the design of automated cells and the fixtures used for robotic welding applications. Participated in design changes and Product changes (GD&T, ISO standards).

Developed Quality Assurance, MIL-STD-810 standards, form fitting and functionality test on off road vehicles.

Initiated PPAP submittals for electrical, powertrain components in support of prototype builds and new product launches.

Developed the detailed designs (CAD, CATIA) and integration into the modular architecture and product configuration.

Responsible for producing 3D design models, drawings and assemblies, BOM’s and other related tasks of the projects.

Performed and reviewed DFMEA/PFMEA analysis. Produced BOM’s in SAP tool.

Summarize quality metrics reports for management review. Management and Organizational Practices Survey (MOPS).

Quality Engineer, Bharat Heavy Electricals Limited, Hyderabad, India Mar 2013- Aug 2013

Daily activities include creating and maintaining quality control documents, testing finished goods to compare them to customer provided specifications, validating detection processes for defective product, creating and performing audits.

Implemented 5S, ISO TS 16949:2009 to emphasize Continual Improvement and provide systematic approach.

Responsible for maintenance & improvement of facility's QMS (ISO:9001).

Created Corrective Action Reports (CAR, SCAR, NCR), implemented corrective and preventive actions (CAPA).

Coordinated with quality and production managers and cross-functional teams in 8D problem solving, root cause analysis.

RELEVANT PROJECTS

Analysis, Improvement & Redesign of Electric Kettle

Designed and analyzed Electric Kettle (Hamilton Beach), Injection molding using DFA, DFM Pro Software and Analysis of Coil material using Solid Works Models, Bench marking Techniques.

Designed, Modelled, Simulated the product operations using CATIA and prototyped using Rapid Prototyping.

Implemented DFMEA to consider and eliminate potential failure modes and effects in the product design.

Lean Six Sigma Black Belt Project, Marquardt Switches Inc., Cazenovia, NY.

Lean six sigma project on Requisition to purchase order process at Marquardt switches purchasing department.

Using DMAIC techniques, improved the Process cycle efficiency from 1.7% to 11.2% and acquired an annual cumulative savings of $100,789. Extensively used MINITAB statistical tool (Expert level) and Excel (V and H- Lookups, Macros).

Worked with Purchasing dept., Quality manager in collecting problems, defining, measuring and documenting them.

Recommended the Purchasing department with improvements to the Requisition to Purchase Order process which Reduce number of defective Requisitions, Lead time for the Requisition, Cycle time & Cost of process.

Fabrication of Electromagnetic piston engine

Designed and fabricated an engine which runs on Electromagnetic effect between an electromagnet and a permanent magnet, Designed manufacturing process of piston connecting rod and used Pro/E to perform solid modeling.

Designed component drawings using Pro/E and PLM tool Team Center.

Implemented DFMEA to consider and eliminate potential failure modes and effects in the product design.

Improving Energy Efficiency of an Automobile (Still in Progress), Syracuse University.

Generated Energy using Wind turbines installed on an automobile while vehicle is moving.

Conceptualized scaled down battery operated car prototype and attach small turbines to compare additional tractive force required after adding turbines with energy generated checking efficiency.

Generated Energy using ‘added elements in tires’ and ‘vehicle’s weight’ (pressure in tires).

COMPETENCIES

Software& Tools: AutoCAD, Pro-E, ANSYS, Solid Works, CATIA, MINITAB, MAPLE, MS Project, HYPERMESH, DFM, DFMEA, VSM, CTQC, Kaizen & Lean Manf., FMEA, Kanban process, Route Cause Analysis (8D), SAP, JIT.

RELEVANT COURSEWORK

Productivity & Quality Engineering

Project Management

Lean Six Sigma and Kanban, DFSS

Supply Chain Systems, JIT

Mechanics of Solids

Principles of Turbo Machines

Design for Manufacturing, DFMEA

Automobile Engineering

Industrial Safety Engineering

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