Quality Engineer Plant

Shubham Shivaji Powar

*************@*****.*** 864-***-**** LinkedIn

EDUCATION

M.S., Industrial Engineering.

Clemson University

GPA: 3.43

May 2019

B.E., Mechanical Engineering.

Shivaji University

GPA: 3.55

May 2016

TECHNICAL AND LANGUAGE SKILLS

Six Sigma Green Belt

ASQ-Certified Quality Engineer (June 2022)

SAP

Minitab

Microsoft Excel with Macro Programming

AutoCAD

Siemens Tecnomatix Plant Simulation

PFMEA

Lean Manufacturing

WORK EXPERIENCE

P3 USA, Inc. Associate Consultant: Warehouse Management Greenville, SC Jul 2019 – Aug 2019

Achieved 70% traceability of existing inventory and implement the FIFO method to manage stocks for put-away using SAP: WMS

Eliminated the generated negative stocks, JITBs (errors) and increased warehouse accuracy by 55%

Identified bottlenecks at receiving dock and solutions to improve performance where possible to implement the ERP system

Supported logistics teams on the receiving dock and provided training to scan the inventory boxes at each node of the warehouse

P3 USA, Inc. Associate Consultant – Quality Assurance Greenville, SC Feb 2019 – May 2019

Supported the Quality Gates of 4 assembly lines to promote the JIT Supply Chain between the Tier-1 supplier and the OEM

Inspected 6600 items/month and detected 310 quality issues/month to ensure customers quality standards are met

Reduced COPQ (Returns and Scrap) from $ 1200 to $ 300 per year using DMAIC, Visuals and Poka-Yoke tools

Identified failures and created Pareto Charts to determine potential root-causes and prioritize improvement opportunities

Used A3 problem-solving tool to carry out root cause analysis for identifying errors and resolved the errors that resulted in 45% increased productivity

Kirloskar Oil Engines Ltd. Continuous Improvement Engineer: Manufacturing Department May 2016 - Dec 2016

Cross-functional Kaizen team member and led a team of 4-6 members for the Kaizen events that caused $22000 annual savings

Cross-verified existing documents like APQP, MSA, Check-sheets, 8-D Reports, and Control Plans

Implemented 5S and Kanban Bins to the work area and reduced downtime by 30 seconds at each station

Reviewed given design drawings with AutoCAD-2013 and SolidWorks, reported solutions to the supervisor

Implemented the vector flow method to manage inventory and increased productivity by 40%

Mahindra CIE Automotive Ltd. Operations Intern Jun 2015 - Dec 2015

Assessed existing processes and reduced waste by 13% using tools like root cause analysis, 5S, 8-waste, PFMEA, etc.

Implemented ABC Analysis to the inventory area, achieving 60% traceability

Designed Value Stream Mapping for the shop floor, eliminated waste using TIMWOODS approach and saved $9000

Assisted engineers with the maintenance of the plant by carrying out tag-outs and lock-outs and supported TPM activities

ACADEMIC PROJECTS AND SEMINARS

Design and Optimization of the Bell Housing Manufacturing Facility

Modeled a manufacturing facility for 6, 8, and 9 transmission bell-housings using Siemens Tecnomatix Plant Simulation software

Carried out machine and tool selection by defining Takt time, MTBF, and MTTR required manufacturing and assembly processes of bell and bearing housings.

Optimized number of machines, workforce, and shift-timings for three different scenarios: (1) Ideal case, (2) Real case, (3) Demand fluctuations up to +/- 30% and developed KPI sheets accordingly

Comparative Assessment of WIPER and Standard Inserts on Surface Roughness and Tool Wear in Hard-turning of Titanium Alloy

Assessed the effects of different speeds, depth of cut, feed on tool wear (tool life) and surface roughness in machining (hard turning) of titanium alloy Ti-6Al-4V using CNC machining

Used Taguchi technique for design of experiment and gray relations, Gray Relational Coefficients and analysis of variance (ANOVA) were applied to study the performance characteristics

Calculated optimum values for performance parameters: Cutting speed (1200rpm), feed (0.15mm/rev), and depth of cut (0.1 mm)

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