Quality Engineer

NIKHIL GADWAL RAMESH

***** ****** ***** **, ***. 106, Novi, MI-48375 (P) +1-313-***-**** ************@*****.***

LinkedIn URL: GADWAL NIKHIL

Summary

Mechanical Engineering Graduate with a Master of Science degree from the University of Michigan-Dearborn having Advanced level certification in CATIA, SOLIDWORKS & ANSYS with experience in the following:

1+ Years of experience as a Quality Engineer in Marimba Auto LLC-Tier 2 Automotive supplier & Sakthi Automotive Group USA, Tier 1 Automotive supplier - Ford, GM & Volkswagen

1 year of Quality & Manufacturing Intern experience at Maruti Suzuki & Signode INDIA Ltd.,

Experience in continuous, product & process improvement tools like APQP, PPAP, 5S, 8D, Control Plan, PFMEA, MSA, SPC, process capability, IATF-16949 Standards

4 years of experience demonstrating strong working knowledge implementing Quality tools in SAE India & International Formula SAE program to analyze various components of a Formula styled race car, ATV & an Effi-cycle

Technical Skills

Quality analysis: APQP, PFMEA, DFMEA, QFD, PPAP, DOE, DFA, DFM, GD&T (ASME Y14.5M), CAPA, 8D, 5S, DVP&R, Cost & Weight Analysis, Pareto Analysis, Pugh Analysis, KANO Modelling, Taguchi Technique

CAD: CATIA V5, SOLIDWORKS, UG’s NX, AutoCAD, PTC CREO

CAE Analysis: ANSYS, Hyper-Mesh, ABAQUS, MATLAB and SIMULINK

Content Editing: Microsoft Office suite.

Others: LMS SCADAS-3, PLM Team center, 3D Printing

Professional Experience

Marimba Auto LLC – Canton, MI (Quality Engineer) 02/2020 - Present

Responsible for new product Introduction and audit documentation according to ISO 9001, IATF 16949 & ISO 14001 standards.

Reviewing new project engineering drawings by analyzing GD&T, tolerances and datums.

Creation, costing analysis of Automotive parts based on type of Manufacturing process, Tooling, Gauging, Material & Annual volumes.

Ensuring supplier PPAPs timing commitments are met on new programs. Verify PPAPs meet the TS16949 requirements are specified by AIAG, internal company requirements.

On-site PPAPs, new supplier Pre-Business Reviews lead in the development, implementation & maintenance of APQP methodologies

Lead a team of quality for incoming parts ensuring all components released to transmission & clutch assembly meet the requirements

Created & inspected Work Instructions, Quality Alerts, I-charts & Managing the customer PPM, Supplier PPM and warranties.

Create & update PFMEA, Control plans & process flow diagrams for new & existing products

Champion 8D problem solving to address customer & in-plant quality concerns

Work closely with QC Lab specialists regarding inspection & non-conformance to expedite supplier CAPA.

PLEX-ERP implementation.

Sakthi Automotive Group USA – Detroit, MI (Quality Engineer) 10/2018 – 01/2020

Assisted in APQP activities by creating & maintaining PPAP Documents for quality verification & DAQ activities to meet customer BIQS & IATF 16949 requirements.

Created & inspected Work Instructions, Quality Alerts, I-charts updating PFMEA, Control plans.

Supervise GP12/safe launch, In Process Inspection check (IPIC) & trained 30 quality inspectors & supervisors on Work Instructions, quality alerts, boundary samples & issues while maintaining 5S methodology to ensure the product quality.

Executed containment actions by defining RCA such as 8D for non-conformance parts, provide CAPA & update control plans.

Performed LPA (Layered Process Audit) to improve quality, reduce scrap, rework & reduce customer rejections.

Conducted internal team meetings & MRB meetings to discuss daily issues on floor & ensure the system implemented is being followed.

Performed Process capability study and reduce process variation using MINITAB software.

Analyzed process variation & controls using SPC tools, process capability study to ensure process/product compatibility with standards

Perform MSA for Gauges, Gage R&R, and layouts for the gauges.

FSAE: Electric - University of Michigan-Dearborn (Design, Development & Analysis of Brakes) 08/2016 – 05/2017

Redesigned Chassis to accommodate the Battery. Utilized CAD drawings from supplier to design braking system using CATIA V5

Proposed the use of ventilated Aluminum disc which reduced the weight by 1.2 lbs. and increased heat dissipation by 10%

Performed Thermo-structural FEA analysis & found temperature rise, deformation & stress due to brake torque (Hyper-mesh)

Designed & fabricated the linkages for brake actuation using CATIA DMU Kinematics optimized the brake pedal force.

Design and Development of Air intake and Exhaust System of a FSAE car

Designed Intake system to incorporate a restrictor of 20mm diameter in a 600cc engine (ANSYS, SOLIDWORKS)

Developed an exhaust system to restrict noise under 100dB as per the FSAE rules for a four cylinder, 600cc engine

Evaluated different geometries with the help of ANSYS Fluent and Ricardo wave

Maruti Suzuki - Hyderabad, INDIA (Quality Intern) 01/2016 – 07/2016

Examined & Implemented SOP periodic maintenance Service of vehicles to investigate & trouble shoot product issues

Resolve non-conformance issues with supplied materials and follow up with suppliers for completion of corrective action.

Generate and track IPRR for the no. of defects occurring through the implementation of Pareto Analysis

Assisted in Conducting supplier quality control audits to ensure vendors and their supplies remain in compliance with company standards

Modeled a chassis used in a truck using CATIA & analyzed for 3 materials cast Iron, Aluminum & E-Glass EPOXY on ANSYS 16.

Created and managed GD&T (ASME Y14.5M) symbols and standards to communicate with quality & manufacturing departments.

Signode India Ltd.- Hyderabad, India (Manufacturing Intern) 06/2015 – 12/2015

Project on Manufacturing of Packaging Sheet Steel straps & seals

Examined & Implemented SOP of Power Strap Machine & Cold Roll Milling

Assisted Team lead in DV & PV testing process & conduct simulation & analysis using FMEA & DFMEA support and gap studies

Investigate issues to discover Root cause and eliminate future reoccurrence on production line

EFFI-CYCLE SAE INDIA - CDGI Indore, INDIA (Roll cage & Brakes team lead) 06/2014 – 04/2016

Designed Roll cage, an ergonomic seat, Ventilated Rotor Disc & 2 pads using SOLIDWORKS

Performed various analysis of the roll cage, seat, ventilated & non-ventilated brake discs (Hypermesh, ANSYS)

Developed DVP, DFMEA, Design Documentation to ensure robust design & timed process

BAJA SAE INDIA - Chitkara University, Chandigarh, INDIA (Brakes team lead) 06/2013 – 04/2015

Calculated & designed Brake system using CATIA V5 & performed Transient Thermal & Structural Analysis using ANSYS

Redesigned & Simulated smaller steering knuckles & discs by decreasing tire size to attain overall weight reduction by 21.5 lbs.

Improved braking, acceleration & maneuverability using AISI 4130 steel tubes over AISI 1018 by implementing DFM/DFA guidelines

Developed and deployed project plan, DVP, DFMEA, cost & weight Analysis & maintained Bill of Materials.

Education

Master of Science: Mechanical Engineering 04/2018

University of Michigan – Dearborn

Bachelor of Technology: Mechanical Engineering 04/2016

GITAM University- Hyderabad, INDIA

Academic Projects

A Six Sigma approach to Eliminate Carpet Brush Marks at Bajaj Carpets

Vehicle Product Development: 2022 Honda CRV AWD LX

Finite Element Analysis of Deep Drawing Process (compression sheet metal forming process)

Custom Automotive Aftermarket Car Door Handles as a Member of SME (Society of Manufacturing Engineers 2016-18)

Multi-Response Optimization of cylindrical Wire Electrical Discharge Turning operation

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