Quality Engineer

Manoj Reddy S Phone: 208-***-****.

Houston, TX Email: **************@*****.***

SUMMARY:

Certified Lean Six Sigma Green Belt with a deep passion for process improvements & scrap reduction.

About 3 years of Quality Engineering experience with Master’s degree in Industrial Engineering.

Goal-oriented individual with strong statistical and problem solving background to drive continuous improvement.

KEY ACCOMPLISHMENTS:

Reduced the cycle time of one process by 30 % by re-analyzing process map of loops on assembly line.

Increased the First Pass Yield (FPY) by 15% by reducing the defects & rework though DMAIC methodology.

Lowered returns by 33% by placing effective permanent counter measures, which saved $19000 each quarter.

Lowered scrap costs significantly by addressing design issues on various difficult to control specifications.

Improved Cpk of various CTQ processes by eliminating special causes & reducing common cause variations on the assembly line.

WORK EXPERIENCE:

Quality Engineer (Process Quality) (Apr 2013 – Aug 2015) Maruthi Industries Ltd (Automotive) (Hyderabad, India)

Responsible for assembly line audits on regular basis and revise, review Standard Operating Procedures(SOP).

Trained team leaders, resources & technicians and led them in quality improvement, cost saving & Lean activities

Collaborated with customers, supplier & internal departments to develop and implement all APQP activities.

Worked with cross functional teams on quality issues & implemented effective Corrective & Preventive actions (CAPA).

Used 8D (5why, Ishikawa), DMAIC & Lean methods to address high scrap issues and to improve efficiency of processes.

Participated in Material Review Board(MRB) in Failure Analysis & employed Corrective Actions to nonconformities.

Prepared PPAPs during process changes acted as first point contact for suppliers and maintained SCAR & NCMR records.

Worked with the team in preparing First Article Inspection(FAI) reports as a part of New Part Introduction(NPI).

Utilized Statistical Process Control(SPC) tools, Capability analysis, DOE, ANOVA to monitor & control the processes.

Acquired knowledge about various Calipers, gauges, CMMs and crack detection equipment such as microscopes.

Designed various Poka-Yokes to improve operator safety, which resulted in improved safety standards in work area.

Performed PFMEA to analyze the risks associated with various processes & updated Control Plans accordingly.

Performed Measurement System Analysis(MSA) like Gage R&R, Linearity, Bias Studies periodically using Minitab.

Monitored KPI’s and conducted Root Cause Analysis (RCA) for creating and executing the action plan for improvement.

Maintained good customer and supplier liaison and addressed their warranty claims, complaints and other concerns.

Continuously improved quality standards to maintain compliance with ISO/TS 16949 procedures.

Production Engineer (Oct 2012 – Feb 2013)

Sai Engineering Industry (Intern) (Pashamylaram, India)

Interpreted the complex part and subassembly drawings (GD&T) and provided support to the technicians.

Created and modified part drawings in AutoCAD with other drafters and engineers’ assistance.

Collected and analyzed data of past equipment breakdown and maintenance to facilitate Total Productive Maintenance(TPM) activities.

Took-part in ECO/ECN board meetings and implemented changes after Engineering Change Order release.

Responsible for maintaining Bill of Materials(BOM), production process & procedures documentation and collect data.

Responsible for developing and updating the Process Flow Diagrams and other documentation work as required.

AREAS OF EXPERTISE:

DMAIC / DMADV methods, Design of Experiments(DOE), GD&T (Blueprint), 5S, Reliability & Maintenance, Statistical Process Control(SPC), Root Cause Analysis(RCA), RCCA, Value Stream Mapping(VSM), Process Capability Studies (Cpk, Ppk), Risk Analysis, Probability & Statistics, D/P FMEA, Control plans, 8-D,5 WHY, A3, Fault Tree Analysis(FTA), Cause and Effect Analysis (Fishbone), Pareto charts, Corrective and Preventive actions (CAPA). Measurement System Analysis(MSA), Problem Solving, Kaizen, MiniTab.

EDUCATION:

Master of Engineering in Industrial Engineering (Aug 2015 – Dec 2016)

Lamar University, TX.

GPA: 3.5/4.00.

Bachelor of Technology in Mechanical Engineering (Aug 2010 – Apr 2014)

Jawaharlal Nehru Technological University, India.

GPA: 3.29/4.00.

SKILLS:

Technical software: Minitab, Simulation with Arena, AutoCAD, Solidworks.

Computer skills: Microsoft Office (Excel, Spreadsheet, Access, PowerPoint & Word), Outlook, ERP systems(SAP), Database application SQL.

CERTIFICATIONS:

Lean Six Sigma Green Belt, Six Sigma White Belt, AutoCAD.

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