AVINASH N MALAVALLI

Ph No: 616-***-**** Email: adbi3z@r.postjobfree.com

www.linkedin.com/in/avinashmalavalli

OVERVIEW & SKILLS

Mechanical Quality Engineer with Six Sigma Green Belt certification and 5 years of experience in automotive and oil industries, responsible for delivering quality controls to proactively address problems, improve product quality, manufacturing flow, customer satisfaction, and increased performance.

• Quality Auditing per ISO 9001:2015 standards.

• Proficient in quality tools like APQP, PPAP, 8D, 5S, MSA, AAR and PFMEA

• Quality Management System: Scrap Reduction & increased productivity.

• National Instrument equipment handling for analysis of bending - spring back measurements.

• Geometric Dimensioning and Tolerancing (GD&T)

• GAGEtrak 7.0, AutoCAD, CATIA V5, Minitab, and MS Office PROFESSIONAL EXPERIENCE

NORMA GROUP, MI, USA: Quality Engineer, May 2019 – January 2020

• Prepared PPAP documents; Control plan, flow charts, process drawings, part submission warrants, etc.

• Interacted with customers for quality feedback on product changes and provided technical assistance utilizing manufacturing quality tools such as FMEA, DFMEA, Process Capability, SPC, and DMAIC.

• Assisted the Quality Manager in IATF 16949 recertification effort through PFMEA and control plan development.

• Managed automotive customer's quality portals in North America for Paccar, Tenneco, Faurecia, and Mack Volvo, in Europe for Eberspaecher, Boysen LLC, in Asian regions for Hyundai etc. and improved key quality performance indicators (KPI) to enhance customer satisfaction.

• Reduced customer complaints by 40% within 6 months by working with the customer and trained the operations team accordingly on in-house inspection to ensure quality was always being upheld.

• Created centerlines for equipment to reduce quality risk and improve machine efficiency by decreasing changeover times by 25%.

• Published Quality Alerts and lead cross-functional teams through 8D processes to identify the root cause through Corrective action and Preventive action (CAPA) process.

• Managed material review boards (MRB) team to reduce scrap of graphite gaskets from 1.85% to .35%.

• Established/monitored work and inspection instructions based on customer-required acceptance criteria.

• Participated in the relocation and redesign of the production cell through improved flow, identification of product by using product flow lines, ergonomic quality tables for inspection and marking activities. AEROSTAR MANUFACTURING LLC, MI, USA: Quality Engineering Intern, August 2018 – April 2019

• Assisted the quality manager with the Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP) for new and existing production parts with changes in the process according to ISO 9001:2015 / TS 16949 standards.

• Monitored the scheduled and unscheduled calibrations, track gage locations, retrieve calibration records, produce calibration certificates, calibration labels and conduct gage R&R.

• Assisted the supplier quality engineer to identify the potential quality problems, lead process improvements to fix causes quality performance metrics to measure with the use of quality tools such as 8-D and 5S problem- solving.

• Monitored contamination using Millipore testing of castings and processed material part.

• Maintained suppliers (NCM) Non-Confirming Material by logging and lead 5S, Kaizen events on the shop floor.

• Secured quick repair instructions with engineering approvals & arranged third parties/supplierrepresentatives to rework non-confirming parts & avoided crisis situations. INDIAN OIL SKY TANKING PVT LTD, MUMBAI, INDIA: Quality Control Officer, October 2013 – August 2017

• Testing - Analysis plan for product verification & validation of vital systems.

• Obtained quality clearances, certificates, and approvals from local and state agencies.

• Identified and helped resolve non-conforming product defects during quality assurance checks.

• Worked with Directorate General of Civil Aviation to achieve workplace safety.

• Pipeline receipt receiving using Pipeline Optimizer software through refineries, storage, and dispatch of the product with quality checks at various stages.

• Assisted the operations manager with the investigation of accidents and unsafe working conditions, studypossible causes and recommend remedial action.

• Participated in the hydrant system commissioning for petroleum/oil handling in the storage terminals at the CSIA. EDUCATION

WAYNE STATE UNIVERSITY, DETROIT, MICHIGAN,

USA Master of Science in Mechanical Engineering, May 2019 Relevant coursework: Lean Six Sigma, Non-Destructive Testing, Advanced Manufacturing, Additive Manufacturing, Project Management, and Industrial Noise Control

VISVESVARAYA TECHNOLOGICAL UNIVERSITY, BELGAUM, KARNATAKA, INDIA Bachelor of Science in Mechanical Engineering, July 2013 GRADUATE PROJECT WORK

• Non-Destructive Testing: Analyzing the vibration motion of a system, proper sizing of the auxiliary that system, the amplitude of vibration of the mass, velocity sensors utilizing a spring-mounted magnet.

• Six Sigma: Improvement of the Purchase Processes for a Non-Profit Organization.

• Additive Manufacturing: Literature review on Material Jetting technique under additive manufacturing.

• Advanced Manufacturing: Literature review on industrial root problem and analysis on the Leak testing machines.

• Smart Stairs: Power generation through a staircase.

• Hydraulic pump and it’s working in drought conditions based on water reservation. CERTIFICATIONS

• Certified Six Sigma Green Belt, Wayne State University.

• Root cause analysis and reporting methods, Michigan Manufacturing Technology Centre.

• Member of American Society of Quality (ASQ), Society of Automotive Engineers (SAE), and American Society of Mechanical Engineers (ASME).

• Yuva global: Non-Profit organization as a creative thinking leader.

• American Red Cross - CPR and first aid training certification.

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