Manufacturing Engineer

Geetendra Kumar Kari

*************@*****.*** 862-***-****

Objective:

Aspiring process improvement engineer to implement lean, six sigma and other industrial engineering practices through continuous learning process by keeping myself dynamic, visionary and competitive with the changing scenario of the world

Education:

Master of Science, Industrial and Systems Engineering GPA 3.83/4.00 till date Aug’18 – May’20

Northern Illinois University, DeKalb, USA

Bachelor of Technology, Mechanical Engineering Aug’11 – May’15

VNR VJIET, JNTUH, Hyderabad, India

Technical Skills:

Hand on experience in Aspen InfoPlus.21, Aspen Process explorer, Aspen SQL plus, SQL, MS office, Functional Testing and Agile methodology

Technical Skills: Aggregate Planning, Inventory Management, QFD, VOC, CTQ, SIPOC, Six Sigma, Pareto Analysis, Hypothesis Testing, Lean Principles, 5S, Poka-Yoke Devices, 8 Waste Categories, Root cause analysis, 5W1H, GD&T, Data analysis and Visualization, DFA and DFM, VSM, Capability Studies, Control Charts, Reliability Engineering, ER Data Modelling, cGMP, GDP, 21 CFR Part 11, 210, 211, Data Normalizations, Kanban, Kaizen events, CAPA, Gantt Chart, Time and Motion studies, FMEA, PFMEA, SPC, TPM, OEE, Process Maps and Cost Analysis for material handling

Software Skills: Minitab, MS office, SQL, DFMA, AutoCAD, MS Visio, SAP, IQ/OQ/PQ, Power BI

Certified in Six Sigma Green belt and Minitab by Lynda

Certified in InfoPlu.21 real time database management system by Aspen technology

Certified in Manufacturing Operations Management, Agile methodology by TCS

Work Experience

Graduate Research Assistant, Industrial and Systems Engineering, NIU, DeKalb, US Oct’19 – May’20

Conducted DFMA analysis on aerator pump of Johnson pump category for SPX flow company to study feasibility of assembly line optimization

Analyzed manual assembly time from time studies conducted in shop floor and assembly time DFA software

Proposed two strategies with required machinery and cost estimations optimizing assembly line to automated assembly line and robotic assembly line

Graduate Teaching Assistant, Industrial and Systems Engineering, NIU, DeKalb, US Feb’19 – Dec’19

Worked as graduate teaching assistant for ISYE – 250 Introduction to lean manufacturing systems and ISYE 440/540 - Production planning and control in Fall 2019

Conducted lean lab sessions to students for calculating Takt time, cycle time, production lead time and quality parameter from time studies

Conducted layout optimization, 5S in lean lab and assists professor in grading exams and projects

Worked as graduate teaching assistant for ISYE – 220 Economic analysis for industrial projects

Manufacturing Systems Engineer, Tata Consultancy Services (TCS), Hyderabad, India Jul’16 – Jul’18

Infoplus.21 shop floor MES application upgradation, migration and functional testing of various MES applications process explorer, ASPEN SQL and LIMS for merger of major manufacturing company

Assisted in upgradation of IP.21 from V7.1 to V8.8 and creating of ASPEN SQL scripts for separation of tags and data

Worked with client’s process engineer teams to identify critical tags and KPI’s which cause breakdowns, analyzed maintenance schedule to improve OEE and to avoid emergency breakdown

Conducted process IQ/OQ/PQ validation and generated trend reports for KPI’s in process explorer

Implemented business integration system functionality testing for each plant and worked as single point of contact for pilot project of deploying system in Azure

Drafted standard operating procedures for process IQ/OQ/PQ validation and developing KPI’s

Estimated efforts consumed for tasks and developed schedule plan for migration activities to achieve sprint goal using Microsoft TFS planning tool

Assistant Systems Engineer, Tata Consultancy Services (TCS), Hyderabad, India Nov’15 – Jul’16

Client is an industrial tools and products supply chain company headed in USA which offers business to business services and sales

Enhanced products 2D deign basing on design for manufacturing and assembly (DFMA) feasibility and cost analysis of materials

Conducted FMEA basing on VOC reports from database and proposed kaizen events to reduce RPN

Forecasted product category volumes and sales with data analytical techniques and generated reports from SQL database

Manufacturing Engineer, Rotec Gears and Transmissions, Hyderabad, India Jan’15 – Spet’15

Design and manufacture different types of gear boxes for heavy machinery which are widely used in steel plants, power generation, mining and reservoirs

Implemented POUS, visual aided techniques and 5S in shop floor for optimized flow of materials like shafts, workpiece holding devices, gear cutters, lubricants and metal chips

Developed process plans, current state VSM for easy identification of delays and NVA

Conducted time and motion studies for 3 different process using ProTime estimation software

Documented implemented kaizen events, drafted checklists for TPM, IQA and EQA

Improved OEE by 20% which increased the company profit by 25,000 USD semi annually

Academic Projects:

Timewise Industries, LMS course project, Northern Illinois University, DeKalb, USA Jun’19 – Jul’19

Timewise Industries is clock manufacturing company lean principles are implemented to meet customer demand

Conducted time studies, identification of wastes and drawn current state value stream mapping

Optimized layout of workstations, proposed POUS and Heijunka sequence

Worked in kaizen events for introducing snap fit for final assembly, combining workstations which have comparatively less cycle times to attain line balancing

The cycle time is reduced from 135.5 sec to 58 sec and production lead time is reduced by 5 min

Neptune Dining Services, Northern Illinois University, DeKalb, USA Jan’19 – May’19

Neptune dining services located in DeKalb have an average footfall of 1250 per day, potential causes for increase of operating cost are identified

Applied data door tools VOC for customer and employees, CTQ, RCA, process capability studies then proposed new inventory management technique and new work schedule for employee

Analyzed past 6 months ordering quantities, frequencies, customer footfall and forecasted footfall for next six months from seasonal regression forecasting

The successful implementation of two proposed strategies operating cost of dining services is reduced by $ 26400 for 6 months

IPPD DFMA course project Northern Illinois University, DeKalb, USA Jan’19 – May’19

Estimated best possible sequence and time for assembly and manufacturing process manually and by using DFMA software on cross travel gear box

Analyzed on economic feasibility, DFA index, CAD models in AutoCAD and ease of manufacturing technique for both existing design and enhanced design with change components

Proposed for replacement of hexagonal screws and washers with thermal shock absorption stoppers, two different components gasket and oil seal are replaced with transmission oil pan gasket

Total no of parts is decreased by 48 after DFMA analysis, cost of gearbox on an average is reduced by 15$ and assembly time is also significantly diminished this improved DFA index

Awards and Activities:

Alpha Pi Mu Industrial engineering honor society organization member from May’19

Recruitment tuition wavier from NIU graduate school’s scholarship committee for Fall2018

On the spot award on Feb 2018 in TCS for execution of complex prioritized ad-hoc tasks

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