Manufacturing Engineer

MANOJ PARUCHURI

adfalk@r.postjobfree.com 994-***-**** linkedin.com/in/manoj-paruchuri

EDUCATION

University of Wisconsin, Milwaukee M.S. Industrial Engineering and Management Sept 2015 – May 2017

CEG, Anna University, India B.E. Mechanical Engineering Aug 2010 – May 2014

ENGINEERING EXPERIENCE

Standard Iron & Wire Works, Nebraska, USA Manufacturing/ Industrial Engineer Oct 2019 - March 2020

Implementing Lean and Continuous Improvement in all elements of the business and facilities.

ISO 9001: 2015 Quality Management System improvement, maintenance and auditing.

Engage with key customers and suppliers to drive alignment and process efficiencies.

Review and maintain all inputs required for the manufacturing of the product (BOM and production versions).

Develop and document training for manufacturing equipment and processes to ensure operators are properly trained to produce product and responsible for the initial training to the initial production team.

Trane (Ingersoll Rand), Lacrosse, WI, USA Manufacturing Process Engineer Feb 2018 – June 2019

Project Leader for Frame Four Insulation project for CTV chiller models where the primary goal is to maintain one-piece flow, keep the unit online and make operators work ergonomically safe and rebalancing the production line. (Cost benefit = 55,000$).

Worked in Operational Excellence team as technical expert and change agent to support the production flow, material flow to the production line, improving visual management on the factory floor, developing pitch boards.

Assisted team leaders in developing key metrics for processes. Supported value stream manager and coach to deploy OPEX training and shared best practices to the team leads and operators and moon shiners.

Applied a problem-solving technique called 9 – Step for Rapid Improvement Event (RIE) to reduce total cost of ownership and make defects per unit (DPU) improvement of 50% (3.56 to 1.78) for our customer. Projected savings cost $2.0 Million.

Ready to Serve team (RTS)- Providing engineering support, assisting and liaising with the Design, Operations and Quality departments to provide swift solutions to issues related to Manufacturing issues and identifying bottlenecks in production using lean site tools.

Creating and developing the Standard Operating Procedures, Standard Works (SW), Job Break down Sheets (JBS) for work cells and operators.

Implemented Lean manufacturing principles and industrial engineering tools like work cell design, line balancing, throughput improvement, one-piece flow, 5S, Standardized etc.

Performing updates for Operation Method Sheets (OMS), implementing corrective actions, conducting safety, 5S and Pitch Board Audits, and Hand-Finger Assessments. Executing time studies.

Process improvements in the plant using Management for Daily Improvement (MDI-SQDIP)- Safety, Quality, Delivery, Inventory and Productivity. Calculated Takt time, Cycle time, Waste time and Walk time.

Optimized the manufacturing process to improve quality and material flow, while reducing cycle times and set-up times. Validating coherence of manufacturing methods employed by performing a series of FMEA reviews with cross functional teams and challenging established processes with evidence and data.

Performance Health, Cedarburg, WI Engineer Intern Aug 2017 – Dec 2017

Executed time studies on medical equipment device manufacturing line for optimizing manufacturing resource, labor and process planning. Calculating avg. worker cycle time and avg. machine cycle time.

Conducted observation and analysis of operators and work procedures to determine time and motion requirements of job duties. Identifying bottlenecks through the data gathered through time studies.

PROJECTS

Trane – Rapid Improvement Event Projects Feb 2018 - June 2019

Changed 2 Tube Rolling work cell Layout to accommodate a floating station so this station can be used as a SWIP (Standard Work In Process) for evaporators and condensers.

Changed the design of fixture stand of control panel bracket to eliminate the unevenness at the base of the control panel bracket when installing it.

Changed the design tolerances when installing the purge tank and control panel bracket to eliminate the confusion for the operators.

Changed the insulation geometry for Frame 4 CTV Chiller models because operators are not able to access the chiller behind the Starter for insulation purposes.

Manufacturing Process in ThyssenKrupp Industries India Pvt. Ltd Dec 2012

Experience with different welding types -SMAW, MIG and SAW. Used NDT methods (Ultrasonic Testing, Dye Penetrant Testing) to identify defective welds and parts. Created training tool for operators (Standard Work, Job Breakdown Sheets). Conducted safety audits and 5S audits.

SAP ERP Simulation Game May 2016

Worked on a mock company manufacturing museli for direct sale and whole sale and analyzed bill of materials (BOM), forecasting, inventory management and running MRP.

Implementation of Six Sigma methodology for University Transportation Services Dec 2015

Used Process Mapping, Fishbone Analysis (Cause and Effect Diagram), Gage R&R, Pareto Charts to reduce the primary metrics which was fuel consumption and secondary metrics which was student waiting time.

The projected savings in the fuel consumption was $5,212.2/month.

TECHNICAL COMPETENCIES / SKILLS

Software/Tools: Minitab, SAP/ERP, AutoCAD, SAS, Pro Modelling, PRO–E, Ansys, Business Planning and Controls Systems (BPCS), Cincom, Windchill, OASIS, MS-Project.

Lean: 5S, 5WHYs, TPM, Value Stream Mapping, Muda, Kan-Ban, Kaizen, 8D, One-piece flow, 9-Step Problem Solving, Rapid Improvement Events (RIE), Process Development, Root cause analysis, Visual Management, FMEA, Risk Register and Assessment.

CERTIFICATIONS

Certified Manufacturing Technologist – (Society of Manufacturing Engineer) (Certification # 000*********).

Lean Six Sigma Green Belt Certification (ProSource Professional Certification) (Certificate#: 18XeL VfquE).

Certified Kaizen Facilitator (Management and Strategy Institute).

Obtained Total Quality Management certification from Expert rating.

Total Productive Maintenance (TPM) & 5S Concept Certified (Management and Strategy Institute).

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