Lean six sigma manufacturing engineer

Balasubramaniam Gnanasekaran

Email: ***********@*****.***

Contact: +1-815-***-****

Education Summary

Degree

Institute

Major / Specialization

Year

Master of Science

Northern Illinois University

Industrial and Systems Engineering

2014-2016

Bachelor of Engineering

Anna University, Chennai, India

Mechanical Engineering

2010-2014

Master diploma in product design and analysis

CADD Center, India

CAE, CAD

2011-2014

Experience Summary

3+ year experience in various engineering tools like FEA, HYPERMESH, MATLAB, SIMULINK FMEA, Manufacturing, Production and customer handling.

Experience in leading design, testing and continuous improvement project in various automobile industries

Extensive knowledge in tools like Control chart, Pareto analysis, Cause and Effect and Histogram

Familiar with FDA, ECE/FMVSS regulations, FMVSS regulations on child restraint, crash protection, seat belt testing, head impact and other procedures

Experience in product design and analysis using design software and simulation of manufacturing process

Extensive knowledge in Engineering tools like Six Sigma, Lean, FMEA, SMED, SPC and SOP

Hands on experience in ERP system and BOM inclusion for sold models 2D & 3D designs

Experience in leading a team of interns in a lean project for process improvement

Worked closely with the project management and marketing team to completely define specifications to help ensure project acceptance.

Application/Areas

Daubert Chemicals, Industrial Engineering Intern, Process Improvement Lead

Northern Illinois University, Graduate Research Assistant, Process improvement

Digi log micro systems, Mechanical engineer

CADD Center projects

Technology Experience

Software Tools

Arena, Minitab, Matlab, MS Office, Autocad, Solidworks, ProE/Creo, MS sharepoint, CATIA, SPSS, SSPP, NX CAM, NX CAD, simens simulation software, ANYS, cape, Tableau, NASTRAN, LS dyna

Technology Experience

Languages

SQL, HTML, C, C++, CNC, G & M codes, C, C++,APDL

Other tools

QC tools, Lean Six Sigma, GD&T, 8D,5S, FMEA and SMED

Domain Experience

Automobile Manufacturing, design, CAE, CAD, CAM, Safety, material testing and Cost optimization

Professional Society / Certification

Member Since / Date Certified

Institute of Industrial Engineers

2014

Society of Automobile Engineers

2011

Master Diploma in product design and analysis

2014

System Dynamics Society

2015

Experience Summary

Employer

From Date

To Date

Northern Illinois University

January 2016

August 2016

Daubert chemicals

May 2015

August 2015

Digi log Micro systems

May 2013

May 2014

In plant training

Companies

Topics

Ashok Leyland

Engine types, Design, Testing, CAE, Probing, CAD, GD&T, thermal and vibrations testing, Star CCM, CATIA, Crash testing, Material properties testing, ANSYS, APDL, LS DYNA, Simulink

Integral Coach Factory

Thermal analysis, Impact testing using LS dyna, Friction testing with nonlinear deformity on different layers, Heat treatment testing and optimization using ANSYS

India Pistons Limited

Molding techniques, Quai Isothermal expansion engine concepts and testing, CATIA V5 models, safety procedures, Annealing and laser cutting, CAE, CFD for fuel nozzle and cylinder head

Experience Profile

Title

Industrial Engineering Intern

Client

Daubert Chemicals

Period

May 2015 – August 2015

Responsibilities

Updated 38 P&ID drawings in AutoCAD Plant 3D to change outdated blueprints, GD&T tolerances per latest ANSI standards

Implemented changes and monitored ERP system data handling in SharePoint for SAP systems

Thermal transient analysis for

Utilized precision measuring instruments and tools (micrometer, caliper, etc.) to accurately gather data for SPC and Inspection

Developed and implemented standard operating procedure(SOP) in quality check stations

Relocation of Lime pumping silo to decrease human work and decrease lead time by 4 hours saving $1.3 M on new equipment

Analyzed Process capability (CAPA) and developed Statistical Process Control Reports (SPC) as part of six sigma project

Performed time study on incoming raw material to implement custom quality testing procedure on each batch for less errors

Achieved high levels of productivity in polymer area by installing new racks saving $200 per load on transportation and overtime using lean and just in time (JIT)

Held meetings and Trained employees on latest quality protocols and importance of database management

Applied lean tools like 5S, kaizen and process mapping to improve the efficiency of the distribution center

Assisted Quality department, when necessary, to ensure proper blueprint interpretation and development of part specific inspection processes

Developed and implemented standard operating procedure(SOP) in quality check stations

Conducted research and mathematical analysis of collected data to ensure all aspects of a product meet the required standards

Experience in maintaining customer relationship in quality assurance, product returns and product take-back.

Title

Graduate Research Assistant

Client

Northern Illinois University

Period

January 2016 – August 2016

Responsibilities

Assisted more than 60 students in their course work relating Total Quality Management (TQM), total product maintenance (TPM) and Lean Six Sigma

Database management, SQL, supply chain analytics, Linear programming, quantitative models are some of the researched fields

Solid works design for DCI/ELM products for packaging techniques improvements

Thermal simulation for PLC components under load during packaging

Planned and coordinated team projects on process improvement resolving quality issues in Caterpillar, FCA,

Teamed with students to implement a procedure change that streamlined the non-conforming material action process in Aurora metals company

Worked on real time projects under professor in patient safety (EHS) by performing root cause analysis and policy analysis in hospital environment

Researched topics under total quality management, and process improvement failures on product quality

Performance improvement for HA-blades using Wind tunnel simulation testing

Knowledge gained on TS 16949, LEAD, Energy start and ISO 16000 certifications

Developed cad model, ANSYS testing and proposed in-house heat treatment which reduced lead time of 8 weeks to 3 weeks.

Learned to prepare failure reports, FDA, SCADA, ISO 9001, 14000 & 16000 certification documents

Analyzed the quality issues by studying histogram, control charts for parts produced and assisted in creation of CAD drawings accordingly.

Conducted several time study analyses for process improvement projects.

Responsible for APQP documentations such as creating measurement plans to suffice/prove product and process

inspection, conducting Gage R&R and measurement system analysis (MSA) for test method validation.

Reviewed Process Flow Diagrams (PFDs), Process Control Plans (PCPs), Process Failure Mode Analysis (PFMEA), Design Failure Mode & Effects Analysis (DFMEA), and Design Validation Plan and Reports (DVP&Rs).

FMEA team member for fastener project and handled multiple Continuous Improvement (Lean) projects.

Title

Mechanical Engineer

Client

Digi log micro solutions

Period

May 2013 to May 2014

Responsibilities

Extended tools VSM, KPI’s, Root cause analysis(RCA), Ishikawa to drive results in wholly sustainable enterprise

Implemented OSHA and EHS standards for better work environments and improve manufacturing facility safety

Performing internal audits for ISO 9001 2008 certification raising company`s value by $1.3 Million

Updated bill of materials(BOM) for assembly using MRP systems

Standardized inspection process and improved tool accountability (poke yoke) on manufacturing lines

Introduced share point and cloud based inspection records in manufacturing plant for ERP systems and SAP

Worked on ISTA/ASTM inspecting and ensuring safe transport of pallets

Layer Vibration testing, Cad modelling and dynamic range test collapse testing using LS dyna

Assisted on wafer level packaging (WLP) and fine bridge ball grid array packaging (FBG)

Worked on Pro-E and ArtoisCAD pallet design to optimize size, weight and cost of transportation pallets

Learned usage of CAPE software to simulate proper lamination for manufactured solar panels during transport

Analyzed the impact of product redesign, activity based costing, life cycle assessment on supply chain

Developed a pool of factors that affect the system dynamic model of green supply chain management

Standardized inspection process and improved tool accountability on manufacturing line

Implementing 5s and Kaizen improvement in assembly line and component manufacturing area

Raised quality assurance by 10% with Kanban cards and color codes

Worked in accordance with packaging team for better packaging of individual packages

Assisted on wafer level packaging (WLP) and fine bridge ball grid array packaging (FBG) improvements to ensure better transport of IC.

Worked on Pro-E pallet design to optimize size, weight and cost of transportation pallets

Zemax, PLC, optical simulation experiences and hands on training

Learned usage of CAPE software to simulate proper lamination for manufactured solar panels during transport.

Supported in identifying new materials and technologies for better packaging and effortless transportation of electronic equipment

Title

Master diploma in product design and analysis

Industries

Hyundai motors, Ashok leyland, Integral coach factory (ICF), India pistons limited (IPL)

Period

January 2013 to May 2014

Responsibilities

Crash test of vehicle chassis to determine the impact on passengers un rear and front end with force calculations for seat restraints

Created hyper mesh for entire chassis to perform fracture testing using ANSYS APDL (ANSYS parametric design language)

Seat belt failures and process failures of head restrains testing using LS Dyna simple understanding

Reverse engineering on H type and N type engines of Ashok Leyland truck engines

Design and CNC code generation of wheels, rims and driving mechanisms using Siemens NX CAD and NX CAM

Learned on standards on ECE/FMVSS regulations, FMVSS regulations on child restraint, crash protection, seat belt testing, head impact

Analyzed 1D flow and fluid solid interaction on smoothed particle Hydrodynamics

Worked on LS dyna modeling for impact test on tennis bat to determine the maximum travel velocity of ball and string tension to achieve it

Used Recur dyne and MSC Adams to simulate multibody dynamics of robotic machine arms to impact test and creep analysis of components

Child safety and seat belt analysis using CREO simulation software to assess impacts

Airbag impact and elasticity force testing during a collision on LS dyna

Passenger safety and ergonomics testing on automobile vehicles

Projects

T-Ramp inspection- Condor manufacturing- created objective quality evidence report-GD&T implementation and correction- redesign and assembly using NX CAD - saving $300,000 in failures and return- CNC code generation in NX CAM

Unit dose filling machine – American Empire Manufacturing- six sigma project– control chart creation- DFMEA – Saved $8000 per batch – SIPOC, run chart, SPC, KPI, Design of Experiments (DOE) creation, limit correction and inspection protocols

Supply chain dynamics – MIT beer model – System dynamics- bull whip effect – linear optimization- database management – MATLAB coding – DOE – correlation and regression model generation – Gap analysis and rectification – reduction of fluctuation in product supply enhancing profit by 70%

Time study – Walgreens pharmacy – Data collection – Delay monitoring – Normalization of data – SPC – Discreet event simulation – Optimization of delays in system - Warm up period – reduced drive through delay by 3 mins per person and walk in delay by 5 mins – achieved by optimizing schedule of employees in peak hours

Radiology and clinical laboratory case study – patient and material flow diagrams - database management diagram - discrete event simulation – ERP system– inventory control – process improvement – reduced waiting time for both in and out patients to the hospital through simulation and resource allocation

Static and Dynamic analysis of MIG welding robot Nozzle with material change – NX Cam model for automated G&M code generation – Tool dimension analysis – Material properties test- life span of tool increased by material change – Dynamic stabilization using multibody dynamics NX Nastran and LS dyna simulation software

Modal analysis on baseball bat and determination of sweet spot – Solid model of bat in NX CAD – free model analysis and fixed analysis in ANSYS – experimental verification of results – dynamic simulation of ball hitting the bat in LS Dyna – sweet spot determination on the bat by determining vibration transmission to handle of bat and max travel time of ball – design modification in NX CAD – CNC code generation in NX CAM

Crash test on chassis- Hyundai – CADD CENTER – Performed material analysis testing in ansys – wireframe model using catia – FEA model verification – structural analysis – results and validation reports

Automated steering mechanism design – CADD CENTER – solid model using creo (pro-E) – assembly – simulation of mechanism – BOM creation and testing – modification in design – Nastran test model – strain and stress on gears using ansys – reports and comparisons

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