Rahul Gami, MSME, PMP, GMP Certified https://www.linkedin.com/in/rahul-gami

addpsq@r.postjobfree.com

Passionate about: Continuous Improvement, Change Management, Problem Solving and Product/Process Design

Believe in philosophy of: ‘Keep it Simple’, ‘Forever a Student’, ‘Observe, Learn, Excel’ and ‘Lead from Front’

15 years’ experience managing implementation of innovative manufacturing solutions for automotive seating, fuel systems components, engines, under carriage components, structural components, medical implants and aerospace components. Managed project worth $50 Million investment for new plant startup. Managed / Mentored Engineers in research and production environments. Collaborated with design engineering team to redesign products for ease of manufacturing (DFM). Led teams through root cause analysis of manufacturing related issues and implemented robust Poka-Yokes. Utilized Six Sigma methodologies, Lean Manufacturing and Continuous Improvement strategies to achieve sustainable benefits.

Well versed and practiced in Project Management with a record of accomplishment in leading high-profile projects including setting up new manufacturing facility in Mexico and Indonesia and turning around an underperforming casting supplier in India to save $14 million/year in shipping costs.

Key Achievements

Managed project for development and Implementation of safety critical car seat manufacturing process in Mexico. This included - Laser welding, MIG welding, Plastic staking and performance testing for 3 million car seats/year.

Spearheaded Advanced Manufacturing division to develop cutting tools to enable cryogenic machining process and develop library of cutting data for various materials processed with CO2 as cutting fluid.

5 years hands on experience with powder bed metal 3D printing. Developed - Design guide, Manufacturing guide, Recipes for materials specific to Caterpillar and Strategies for Post Processing & Validation.

Patented processes for fuel system component manufacturing to improve fatigue life and reduce cavitation. This included Autofrettage process, Precision Electro Chemical Process (PECM) and Laser Drilling.

Led Six Sigma Black Belt project to Improve steel casting supplier performance to eliminate expedite shipping cost of more than $14 million/year.

Designed fixtures for laser welding/testing of car seats, hydraulic component machining, chassis component machining /welding and fuel system component machining.

Conducted Design for Manufacturing / Assembly (DFM/A) to improve process efficiency.

Granted 5 patents: 2 for product design, 1 for process design and 2 for fixture design.

Career History

Fusion Coolant Systems, Canton, MI Sept. 2019 – April 2020

Director of Advanced Machining

Responsible to manage and lead manufacturing research team (3 Manufacturing Engineers and 2 operators).

Developed Manufacturing Engineering team to research, evaluate and improve machining (turning, drilling and milling) Titanium, Inconel, Cobalt Chrome and other difficult to machine alloys.

Created departmental budget for FY 2020 and forecast for FY 2021.

Implemented processes to ensure consistent data collection methods and analysis.

Steered manufacturing R&D group to expand potential applications, such as - hobbing and grinding process for super critical CO2 technology

Eliminated redundancies and implemented standard protocols for communication, process stabilization, process design and data collection/identification/storage & reporting with Fusion Coolants patented technology for Medical, Aerospace and Automotive customers

Developed business plan to improve technology for easy adaptability and expanding customer base.

Identified, collaborated and partnered with cutting tool OEM’s to modify and adapt their products for CO2 application to expand Fusion’s as well as their customer base.

Submitted patent for tool design to be used with cryogenic cooling.

Lear Corporation, Southfield, MI March 2017 – Sept. 2019

Senior Project Manager / Team Leader, Advanced Manufacturing

Responsible for managing portfolio of Ford front row seats

Led a team of 12 personnel’s, which included manufacturing engineers, maintenance engineers, quality engineers and technicians to produce safety compliant seats.

Led the development through production launch of metal seat structures and mechanisms.

Developed and managed $50 million capital investment budget.

Performed capacity analysis to identify number of equipment’s and operators needed to produce 3 million seats per year.

Utilized Lean principles to minimize various wastes, such as – defect/rework, waiting, motion and over processing.

Performed ergonomic assessment for operator health and safety.

Prepared quote requests for new products

Reduced manufacturing complexities by conducting DFM activities with Product Engineering team to ensure parts and assemblies are designed to allow manufacturing best practices to be used.

Managed all aspects of equipment and tool build at external equipment integrators

Conducted GEMBA walk when at plant

Maximized efficiency by analyzing line layouts, workflow, assembly methods, change-over-fixtures and tooling, gauges, work-in-process (WIP) handling

Collaborated with Quality Engineers to Develop Advanced Product Quality Planning (APQP) requirements such as: Quality gates, Process Failure Mode & Effect Analysis (PFMEA), Process Flow Charts, and Control Plans.

Main point of contact with production plants throughout the program development and launch, and responsible for technical support as needed thereafter.

Generated macro-schedules to ensure that all project milestones are tracked and completed on time.

Caterpillar, Inc., Mossville, IL and India January 2008 – November 2016

Senior Program Manager / Team Leader, Manufacturing Research – Mossville, IL (June 2012 to November 2016)

Responsible for implementing new processes, continuous process improvement and quality improvement projects.

Managed teams to implement Quality System and Capital Purchase at new facility in Indonesia

Initiated Continuous Product/Process Improvement activities to reduce scrap rates of hydraulic, engine, fuel system and structural components at various facilities

Developed, Managed and Implemented alternative manufacturing technologies such as – Metal 3D printing, Micro-Foundry, Autofrettage and Precision Electro-Chemical Machining for fuel system components NPI.

Managed manufacturing support for CR600/1350 Fuel System NPI team, Low-Cost Engine program, and Next-Gen Fuel Systems NPI team.

Developed additive manufacturing design and process guides, and PFMEA.

Designed production intent tooling using CAD ProE

Developed Autofrettage process for fuel injector and pump components to improve fatigue life and reduce/prolong cavitation damage. Received a patent on this design.

Developed various remanufacturing processes for fuel system components.

Developed a Precision Electro Chemical Machining (PECM) Process for fuel system components.

Designed various welding and machining fixtures.

Identified and evaluated robotic machining systems for cutting sand blocks to produce prototype castings.

Implemented two projection-based assembly assist systems.

Program Manager, Supplier Quality – Chennai, India (June 2011 to July 2012)

Responsible for improving supplier quality, part cost reduction, supply chain, process efficiency and capacity improvement.

Led turnaround of an underperforming steel casting manufacturing operation in India to improve quality and delivery performance

oManaged a cross-functional team of design engineers, buyers, advanced manufacturing engineers and supply chain professionals to improve the overall efficiency of the steel-casting suppliers and review PPAP documents.

oFacilitated rapid improvement workshops (KAIZEN) at supplier facilities

oCreated prioritization matrix for supplying casting to Caterpillar plants in Decatur, IL and India.

oIdentified process bottlenecks and developed a lane strategy to improve throughput

oStreamlined operations and supply chain activities resulting in cost saving of $14 million/year.

Research/Development Engineer – Mossville, IL (January 2008 to June 2011)

Conducted research into new methods of machining and improving component manufacturing quality

Led teams to optimize/improve existing manufacturing process and part quality at various Caterpillar facilities.

oPerformed root cause analysis for manufacturing quality issues on hydraulic valves and cylinders, sand casting process, motor grader undercarriage assembly leakage issues, and engine block machining.

oDeveloped process FMEA for new and existing processes.

Developed fixture design concepts for large component machining.

CGN & Associates, Peoria, IL March 2007 to January 2008

Senior Engineering Consultant

Developed low-cost suppliers for hose and brass fittings in India for LR Nelson industry.

Performed Gage R&R activities and design sequencing activity and analysis for the Engine Development Group.

Audited suppliers for MQ12005 certification (Caterpillar supplier certification)

Performed PPAP screening for new purchase finished components. Developed Control Plans and PFMEA’s.

Delphi Automotive, Shelby Twp, Mi October 2005 to March 2007

Manufacturing Engineer (Contract)

Responsible for improving fixture design analysis, process improvement, root cause analysis and cutting tool design

Designed fixtures for various automotive component machining.

Trained engineers on process improvement techniques.

Performed 8D analysis and Corrective actions to reduce scrap rate of steering assembly from 8% to less than 2%.

Improved the functional accuracy of Fixture analysis software developed at Delphi Research Labs.

Designed new cutting tools and improved product quality while machining steering and engine combustion parts.

Education & Professional Development

MSME, Michigan Technological University, Houghton, MI

BSME, Nagpur University, Nagpur, Maharashtra, India

PMP Certification, Project Management Institute

21 CFR Part211 GMP Certification, BioPharma Institute

PLC Programming from Scratch (PLC I), Udemy

Practical PLC Programming (PLC II), Udemy

Work Authorization Status

US Permanent Resident (Green Card holder)

Contact this candidate