Sai Babu

*** ******* ***** ***, **** #***, Las Vegas, NV 89144

Phone: 612-***-**** ad4upi@r.postjobfree.com

April 12, 2023

Dear Recruiter:

Position applied: Plant Manager or suitable position. Willing to relocate.

US Citizen

SUMMARY OF QUALIFICATIONS: Master of Mechanical Engineering degree with a 4.0 GPA from University of Missouri S&T, I bring 25+ years of experience with P&L responsibility leading up to 30 direct in automotive, as Plant Manager, Engineering manager: Process Development, Product Development, and Launching with Lean Manufacturing. I have been the first technical contact & a solution partner for our customers in their development/problem solving.

Quoted with clear documentation of casting orientation, split lines, feeding system to address customer requirements: mechanical properties, leak test parameters, and setups for trimming, machining, CMM, and risk factors in achieving the lowest cycle times.

Product development and new launches exceeding quality requirements and cost budgets.

oTooling design and development using Unigraphics NX, Solidworks and Catia. Increased tool life by calculating clearances for thermal growth and uniform die temperature. Trained designers with industry’s best practices and procedures.

o Tooling manufacturing: extensively worked with CNC, CAM programming and complicated CNC setups. Lead teams with quick die Mfg., assembly and spotting.

o Process development using PQ^2, EKK & Magma: flow, porosity, Stress/Deformation Analysis. Established the process for 100+ brand new castings from scratch or for the takeover tooling using DOE and Visi-Trak. Lead and trained process teams.

oGuided and lead machining teams in new fixture, program setups and trouble shooting.

Developed /maintained Value Stream Mapping, Standard Work, Visual Management, 5S, Variation Reduction Kaizen, Material Pull System, TPM, Six Sigma, Poka-Yoke, and Quick Change Over to address the shop floor issues and to reduce the downtime.

Supported QA to keep up manufacturing process capabilities (Cp/Cpk) on daily quality issues.

Trained and guided die maintenance technicians: In quickly adapting to new die mechanisms, safe dismantling and reassembly. Helped maintaining delicate die components. Planned and arranged for regular PM, replacement inserts and replacement dies.

Travelled and stayed in China, Taiwan, Singapore, Italy and Germany for negotiating the tooling prices, design approvals, die inspection, assisting sampling with die cast process and trouble shooting in tool corrections with dimensional analysis and Xbar-R charts.

Active management team member for ISO, TS, IATF and CQI-27 certifications.

Sincerely,

Sai Babu

Sai Babu

220 Emerald Vista Way, Unit #140, Las Vegas, NV 89144

Phone: 612-***-**** ad4upi@r.postjobfree.com

SUMMARY OF QUALIFICATIONS: Master of Mechanical Engineering degree with a 4.0 GPA from University of Missouri S&T, I bring 25+ years of experience with P&L responsibility leading up to 30 direct in automotive, as Plant Manager, Engineering manager: Process Development, Product Development, and Launching with Lean Manufacturing. Expert in High pressure die casting in tooling and process, fluent in 3D CAD, Ansys & NX Nastran FEA, EKK, MAGMASOFT flow. Developed one of the highly useful PQ^2.

WORK EXPERIENCE AND MAJOR ACCOMPLISHMENTS:

Advanced Engineering Manager L3 Harris, Londonderry NH 9/2019 –Till date

L3Harris is an agile technology innovator in space and defense (A&D).The NH division leads in the design and manufacture of night vision equipment, electro-optical devices and communication systems.

Lead the advanced engineering team to test all product designs with DFM, NX NASTRAN Stress Analysis for user thermal, vibration & environmental conditions, Moldflow, GD&T reading and interpretation of ASME Y14.5, MIL-Standard documents.

Train Supplier Quality team and suppliers to identify the quality issues, root cause analysis, gating and venting locations, molding and machining process development through tool design.

Train Supply Chain Team on part and product cost estimation for target pricing; consolidate family parts to optimize vendor automation, and in-process inspection for cost savings.

Lead the NPI teams by ensuring the entire product line >50 parts are received per schedule.

Expertise in the development of PEI molded parts filled with carbon and glass fibers, Titanium, SS, Aluminum alloys, secondary CNC machining, heat-staking, and EMI coatings.

Plant Manager Future Die Cast, Detroit MI 8/2012 –8/2019

Future Die Casting is a highly competitive die caster specialized in new product development with Prototype and low volume aluminum and zinc castings with 600T to 1200T die cast machines. FDC’s key strength is 4-8 weeks product development center with in-house engineering, Mold flow simulation, Tool building, X-ray testing and quick die change systems.

Led Quoting, Moldflow, Engineering and Die Cast Process Development directly and Production Control, Die Casting Production, Tool building, Maintenance, Program Management, Purchasing, Shipping & Receiving through 5 key managers. Increased OEE by 8% with 98% on-time delivery.

Achieved mastery in die-cast process development using mold flow, Doctor Die cast and PQ^2 software’s. Trained and nourished the team who commands the highest talent in making sound castings on average of 6 to 8 brand new parts per month.

Responsible for generating profit for each casting, and also for balancing workload for a monthly profit after all expenses.

Turned a bankrupted company running with single shift with 78 people to Profit making with three shifts operation with 132 people by constantly training and supporting three shift teams with solving both technical and human relations problems.

Introduced First piece inspection and hourly inspections methods before moving bins to the next operations in the flow. Initiated traceability techniques with color codes, bar codes, and sign off sheets. Separate Rework and Repair cells introduced to help increase the yield by 28%.

Die cast Tooling Manager: GH Tool Inc. Washington MO 1/2006 –7/2012

G.H. Tool Inc is one of the most profitable organizations with ISO and AS-9100, designing and manufacturing of die casting dies for automotive and aircraft industry.

Calculated PQ^2: forces, heat, FEA, runner and gating for optimum fill conditions

Improved engineering standards and procedures. Coached/ mentored Designers

Introduced innovative solutions for a 10 % increase in OEE & 25% reduction in cycle times

Leading both Engineering and manufacturing teams making new dies, rebuilds and also die maintenance repairs. Led (unionized) 3-CAD designers, 3-CAM programmers, and an EDM leader. Avoided 95% manufacturing errors by constantly updating process planning. Doubled dies/month by adding 4-axis milling & Plano miller, solid graphite electrodes, Erowa electrode and work holders.

Sr. Design Engineer and Project Manager: BBI Inc., Guelph, ON, HQ: MI 11/2000 –11/2005

BBI is a tier-1, QS-9000 and ISO-14001 registered manufacturer of a complete range of interior vehicle components for Chrysler, GM, Ford, Toyota, Honda, Nissan, Subaru and DOD parts.

Did 250+ plastic injection molded parts with > 60% with fiber reinforced. First time ok at least 45%.

Made a few parts with metallic and plastic inserts to reduce the wall thickness. Made about 16 parts with reverse stressed geometry to get the intended geometry. Used conformal cooling to evenly distribute the thermal stresses that helped increase the mold life +50,000 to 200,000

Coordinated with suppliers: Traveled to Taiwan, Italy, Singapore, Germany and Switzerland for tooling procurement: assessed vendor capabilities, negotiated techno-commercial terms, approved mold-designs, and organized pre-shipment trials.

EDUCATION:

MS in Mechanical Engineering 2009-11 University of Missouri S&T, USA

MBA in International Business (First year) 1999-2000

Bachelor in Mechanical Engineering 1985-1989

MAJOR TRAINING:

HPDC Processing and tooling design Oscar Frech GMBH, Germany

HPDC Gating Design and other courses NADCA

Mold Flow and Stress Analysis EKK, Farmington Hills, MI

CATIA- V5 Practical Catia, Algonac, MI

Ansys FEA (Finite Element Analysis) Mechanical Dynamics, Toronto, ON

Unigraphics version 16, 18 to NX7.5: EDS, Toronto, ON and GMU, Warren, MI

HOBBIES & INTERESTS: Read & practice Leadership Principles of Dale Carnegie & Stephen Covey.

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