Arun Sahil Vampugalla

adch3f@r.postjobfree.com 248-***-**** https://www.linkedin.com/in/arunsahil-vampugalla/ SUMMARY:

• Experienced in Quality Engineering working as a Quality Engineer representing Tier-1 suppliers at OEM’s (FORD-LTP, VOLVO Cars-SC, GM-Warren Technical PPO, FCA-SHAP)

• Experienced in Manufacturing/Production Engineering related to Heavy Machineries dealing with CNC programming, Process/flow charts, Product development, Cost reduction and Assembly Procedures.

• 1.5 years of Industrial Internships as a Production/Quality Intern in Heavy Machinery and Auto-Component Industries.

• Experience in Team Leadership, Technical Documentation and Team Coordination with Cross-Functional Teams.

• Passionate and Experienced Mechanical Engineering Graduate with good Technical and Problem-Solving skills seeking Full- time/Contract Opportunities.

• Certifications: American Society of Quality (ASQ)- CQE, CSSGB – Expected Apr 2020

• Student Member- American Society of Mechanical Engineers (ASME), Society of Manufacturing Engineers (SME) SKILLS:

Core Skills: G8D, 5Why, Root Cause Analysis, G R&R, SPC, GD&T,Lean Six Sigma, APQP/PPAP,DFMEA/PFMEA, DFM, DMAIC, Poka- Yoke, PDCA, Kaizen, 5S, DVP&R, SMED,JIT,TPM,VSM,Blueprint Reading, Implicit & Explicit CAE Analysis CAD Software: CATIA V5, Pro-E CREO 2, Solidworks,AutoCAD, UG NX9.0,Teamcenter-Siemens CAE Software: Hypermesh, Ls-DYNA, Ls-OPT, ABAQUS, ANSA, ANSYS Application Software: MATLAB-Simulink, MiniTab, MS Office, MS Project, SharePoint, Microsoft SQL server, Microsoft Visual Studio.

Control Systems: G&M Code programming,Cadem-CNC turn-mill,MaterCAM,Delmia EDUCATION:

Master of Science in Mechanical Engineering – Wayne State University, Detroit, Michigan. [May-2018, GPA-3.45] Master of Technology in Computer Integrated Manufacturing (CIM) – SRM University, India. [Apr-2016, GPA-3.61] Bachelor of Technology in Mechanical Engineering – K L University, India. [Apr-2014, GPA-3.40] WORK EXPERIENCE:

Quality Resident Engineer TRIGO Global Quality Solutions, July 2018 – Present Stackpole Intl- FORD Livonia Transmission Plant (LTP) Oct 2019 – Present

• Responsible for Supplier Quality issues of Stackpole Intl’s (10R,6R,10R-MHT) hydraulic oil pumps for Transmissions at FORD- LTP (Livonia Transmission Plant).

• Responsible for Reduction of Quality Rejects, Dock Holds, Stop Shipments, Warranty Claims-ECB’s, FTT Rejects,APR(assembly plant returns) and FSA of oil pumps(10R,6R,10R-MHT).

• Performed and reviewed 8D With Plant Contacts and Ensure That Robust Global 8Ds Are Sent to LTP On Time and drive for 8D closure for open rejects and participated in stage 1 quality disputes with Incoming Quality.

• Reviewed QCN’s(Quality concern notification) between supplier and Ford-Incoming Quality(IQ) and Supplier Technical Assistance(STA).

• Assisted in PPAP/APQP review and submission related to PFMEA,Control Plans,MSA from supplier to Ford-STA.

• Performed cross functional problem solving with system/design/ production departments with respect to design changes for wire harness and sensors and gauges and resolving quality issues related with pumps.

• Performed and assisted to lead Lean six sigma technical 6 panel (DMAIC) on supplier issues

• Assisted in GD&T review of pump components and responsible for submission of engineering change document TPD and GR&R.

• Reviewed 2D and 3D CAD prints for pump components with regards to tolerance and design/print checks. Gestamp- VOLVO Cars- Charleston South Carolina Feb 2019 – Sept 2019

• Responsible for the Supplier Quality issues of GESTAMP which supplies exterior body components (BIW) (Roofs,Doors,Wheel houses,Floor panels,Fenders etc) which constitute 90% of Body parts at VOLVO Cars.

• Performed Root cause investigation and 5 Why’s analysis of each defect/issue which arises during production and 8D quality analysis of issues.

• Responsible for interaction between Gestamp Quality Team and VOLVO’s Supplier Quality management team to achieve immediate Engineering changes or Reworks to the parts.

• Responsible for Effective reduction of Quality Rejects (QR’s) by 50% and taking the supplier off the escalation list.

• Assisted in PPAP review and submission to the Customer regarding any engineering change approvals, Tooling change,TPD’s and PFMEA documentation.

• Performed and generated daily Quality Audits of parts and Root cause analysis reports of all the issues. Magna Formex- GM Warren Technical Center (PPO) Jan 2019 – Feb 2019

• Responsible for Quality Inspection of Truck chassis from Magna formex (Frame supplier) at GM warren technical center

(PPO).

• Responsible for final approval of chassis to the assembly line which involves various Quality checks such as Drag welds, pitch checks, Exhaust hangers, Bushing, Pins,thread counts.

• Performed Design (Quality) analysis and resolved issues of chassis with GM engineering Team and performed Liaison services between Magna formex and GM.

Cooper Standard- FCA-Sterling Heights Assembly Plant (SHAP) July 2018 – Dec 2018

• Responsible for inspection process for Fuel Line Bundle part for contracted customer (Cooper Standard CS and FCA- Sterling heights assembly plant-SHAP) with ThyssenKrupp(TK) (sterling heights) and performed Quality audits such as Root cause analysis, observation reports and quality process reports.

• Performed visual, mechanical and functional verification of fuel bundle lines (RAM truck) to ensure compliance to set specification and Quality standards.

• Collected and recorded accurate data regarding defects in fuel bundles and tagged and isolated defective parts and provided justification for defective fuel bundles.

• Performed analysis of problems at SHAP’s facility to find the proper solution (avoid claim) and inform affected production plants to take appropriate corrective actions. Proactive channeling of information on existing claims to the Plant to perform the analysis and solve them.

Manufacturing Engineer Rachana Machines Pvt Ltd, India June 2014 - May 2016

• Responsible for preparation Production Process Sheets for the components of specially ordered machineries like paper cup making machines and Rotary Indexing Machinery-Five, six Station

• Load Charts for the individual components and entire machinery of paper cup making machines and Rotary Indexing Machinery-Five, six Stations.

• Allocated work to the CNC machine shop and assisted in CNC programming-G&M coding for the production of individual components using MasterCAM.

• Responsible for engineering and design modifications to lathe components using Solidworks and carrying out FEA/stress analysis using ANSA/ANSYS.

• Responsible for updating CNC machining parameters like tolerances (GD&T), feed rate, Canned Cycles using MasterCAM.

• Responsible for implementing MRP of the lathes depending upon the incoming parts from suppliers depending upon their functionality.

• Co-ordinated with the Assembly and design departments for the effective deliveries of the machineries.

• Performed Quality Assurance and inspection of the individual components of the machinery. Production Intern India Pistons Pvt Ltd, India Feb 2016 – May 2016

• Assisted in optimization of Assembly flow activities and Line balancing for Pistons- Passenger cars/commercial vehicles, Pistons rings and Cylinder liners production lines.

• Performed Ergonomic evaluations, time studies and process charts using Delmia for pistons with bore dia 80mm-150mm depending upon their power outputs and injection pressures.

• Assisted in detection and prevention of defects with lean manufacturing tools-5 why’s for pistons rings made of high alloy steel containing 17% carbon content.

• Assisted in Achieving manufacturing efficiency by analyzing and planning work flow, space requirements, and equipment layout for Pistons production line by KANBAN, JIT, VSM Lean tools. Product Quality Intern Hindustan Machine Tools (HMT), India July 2013 - Jan 2014

• Assisted using the development and implementation of quality audits system, process sheets.

• Testing and inspected products for flaws and quality by comparing; recording any malfunctions by involving in the complete product development life-cycle.

• Performed the tasks of ensuring the ISO standards of the product by coordinating with the quality systems staff

• Performed responsibilities of assisting senior quality engineer with multiple tasks including testing and fabrication. Plant Maintenance Intern Visakhapatnam Steel Plant, India May 2012 - July 2012

• Assisted in carrying out routine scheduled maintenance work and responding to equipment faults.

• Diagnosed the breakdown problems and performed quality inspections on jobs.

• Informed Maintenance supervisor about potentially dangerous mechanical equipment and faulty instrumentation. Student Employee-Wayne State University (WSU) dining Services Aramark,Detroit,MI Aug 2017 - May 2018

• Worked as a Sushi Chef, Cashier and student lead and managed the whole team effectively in prime rush times. ACADEMIC PROJECTS:

CAE - Crash Worthiness and Occupant Safety WSU,Detroit,MI FMVSS and IIHS Front, Side, Roof, and Rear Crash Test

• FE Analysis Test as per FMVSS 208, 214, 216 and 301 and IIHS Moderate, SORB, Side and Rear Impact Test.

• Head-on vehicle collision impact with 50th Percentile detailed Hybrid III Dummy, Airbag and seatbelt at 25%, 40% and Full- Frontal Impact.

• Model setup in LS-Prepost by constraining the bottom rails and providing a static load to the forward edge of Vehicle’s roof using a rigid unyielding rectangular block 762mm to 1892mm per FMVSS-216 standard.

• Validated Strength to Weight ratio involved in quasi static roof crush as per FMVSS 216 regulation.

• Vehicle Integration using Hypermesh and LS-Dyna for dummy positioning, car positioning, velocity definition, contact definition and output cards.

• Deformation and Energy Density Flow Analysis using LS-Prepost, Hyperview and Hypergraph and Dummy injury criteria study such as HIC and chest deflection, with and without seatbelt and Airbag.

• Attained 10% reduced intrusion by designing Honeycomb Crashbox & Side Impact bar for Front & Side Impact and Modified A & B Pillar with HSS, Roof Rail with Boron and Rails with Composites to improve structural integrity. Thermal Stress/Strain Analysis of Flip Chip (IC) Package & Automotive Bracket Stress Analysis WSU, Detroit,MI

• Analyzed thermally induced stresses, strains and elastic deformation in Flip Chip assembly and solder joints.

• Finite element analysis (FEA) using ABAQUS was employed to study Thermal cycling loading for solder joint fatigue life.

• Plastic Deformation analysis of Automotive Bracket under Static Loading and obtained 18% & 20% reduced Stress and deformation by redesigning the bracket using CATIA and modifying material A Knowledge Based Expert System for Piston Rings in Permanent Mold Casting Process India Pistons Pvt Ltd,India

• Developed and implemented Expert system methodology in INDIA PISTONS LTD Chennai which can suggest metal grades for production of piston rings and predict defects and remedial ways to reduce defects.

• Developed SQL based expert system by IF/THEN rules based upon the metal grades used in the company and developed Visual Base with Microsoft Visual Studio 2012.

• Developed expert system made efficient reduction in production losses for piston rings by predicting the defects and suggesting the metal grade for ring upon type of mold, cavities, type of gates, ejection system, allowance and composition. Quality Control and Non-Conformity Analysis of Products Hindustan Machine Tools (HMT) Ltd,India

• Performed quality inspections on various finished products and lathe machines.

• Performed reverse engineering on a robotic arm by documenting disassembly and bill of materials which stated input and output function of each part.

• Performed special techniques like Coordinate Measuring Machine for the Quality Control inspection of various finished/defected parts of the Lathe/Mill components.

• Redesigned a Lathe component which is Lead screw with needle cage rollers to reduce overall manufacturing cost of the product.

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