Quality Engineer Engineering

Karan Dutt, MEng

682-***-**** • *************@*****.*** • https://www.linkedin.com/in/karandutt0900/

Evansville, IN, 47715

Quality Engineer – New Model Launch

PROFESSIONAL SUMMARY

Results-oriented professional with over three years of experience consistently creating value and improving quality processes in the automotive industry. Strong change agent with outstanding leadership skills, hold a strong vision, superb critical thinking and analytical skills, and the ability to implement innovative best-in-class strategies to support corporate objectives. Have hands-on experience launching new models and lean, automated production lines while working cross-functionally in a collaborative environment. Open communicator, foster a continuous improvement culture within the organization, develop rapport, and nurture relationships with internal and external stakeholders.

SKILLS

Project Management

Cross-Functional Team Leadership

Quality Management

Quality Control

Customer Quality

Supplier Quality

Process Improvement

Root Cause Analysis

Continuous Improvement

CAPA

APQP

PPAP

FMEA

DMAIC

Kaizen

5S

Troubleshooting

Manufacturing Engineering

Lean Manufacturing

GD&T

Value Stream Mapping

SPC

ISO/TS 16949

ISO 9001 standards

Poke Yoke

Internal and Supplier Audits

New Product Introduction

CERTIFICATIONS AND TECHNICAL SKILLS

Certified Lean Six Sigma Green Belt, IASSC, 2017.

Project Management Professional certification (PMP - in progress), PMI.

Certified CATIA V5, Alma Mate Info Tech, 2013.

MS Office Suite (Word, Excel, PowerPoint), SolidWorks, CATIA V5, Ansys, Icepak, MATLAB, Minitab, AutoCAD, Quality Workbench.

WORK EXPERIENCE

Toyota Boshoku Indiana, LLC, Quality Engineer 2 Mar 2017 - Present

Princeton, Indiana

Launched new product with an innovative design philosophy for first time in the United States, with monthly sales of $3 million, a 15% - 20% monthly increase in profit margins, a sustained 90% of operational availability (OA) after three years of launching, and less than 0.5% scrap after three and half consecutive years of production.

Slashed the cycle time by 3 seconds increasing the Operational Availability (OA), quality of output, and volume, leading to $1 million in new business.

Reduced customer claims by 70% during the first year of production, outperforming the previous supplier of the same part.

Increased the process window for automated assembly equipment by implementing DOE at the supplier site for injection molding parts and changes on the assembly equipment at Toyota Boshoku, reducing the failure rate at the gate from 80% to 0.7%.

Championed strategic engineering changes including the elimination of two positions, and the introduction of a new and optimized packaging design for supplier, leading to an optimized operational availability, reduced cost of quality and operational waste to less than 1%, and generating $60K in cost savings.

Achieved quality and personnel annual cost savings of $30K by eliminating one position, streamlining quality control processes, and integrating semi-automated Statistical Process Control system.

Reduced scrap rate through the addition of PLC program to reuse component parts.

Awarded promotion to Level 2 Launch Engineer for consistent outstanding performance.

Play leading role as liaison between technical center, plant, customers and suppliers. Provide technical assistance in regards to equipment (PLC/Tooling) and design (Drawing/GD&T).

Ensure the product launch phase is on schedule, and that product meets customer expectations.

Troubleshoot critical customer complaints providing effective solutions that result in high levels of customer satisfaction.

Lead product and process development activities ensuring compliance, readiness and timely delivery to customer throughout the entire cycle.

Cultivate working partnerships and drive results cross-functionally through effective product launch planning

and goal- setting activities, facilitating training to achieve KPIs target, leading meetings with involved

departments to solve customer issues, and executing effective countermeasures.

Implement creative methodologies to develop new manufacturing processes, including an innovative

production flow design, effective assembly methods, quality inspection, and top-notch technology in equipment production.

Develop design of experiments on current weld/assembly cells to reduce the variation in output.

Create quality plans to monitor and improve supply chain and part/process qualification requirements to

ensure that manufactured products meet drawing specifications and quality/reliability requirements.

Perform supplier development activities including regular visits to supplier to validate production capability,

documentation, tooling, and processes, ensuring production meets MQC.

Apply continuous improvement principles to ensure robust and improved manufacturing processes and a high-quality product.

Create and manage quality assurance documents including quality assurance plan, tool progress report, evaluation plan, supplier and customer quality standards, Process Failure, Mode Effects Analysis (PFMEA), and Manufacturing Quality Chart/Control Plan (MQC/CP).

Maruti Suzuki India Ltd, Intern Jun 2013 - Aug 2013

Gurugram, India

Led project ''How to improve Maintenance Department'' to improve processes and optimize machines performance in the shop.

Optimized the Equipment Management System designed by IBM by Introducing easy use of scanning for

team members, and a notification system for technicians on preventive maintenance schedules.

Resolved the misalignment in the hangers of conveyor belt by conducting and analyzing efficient design of experiments (DOE).

Headed and facilitated Kaizen projects fostering continuous improvement of the department.

EDUCATION

Master of Engineering (MEng) in Mechanical Engineering, University of Texas at Arlington (UTA).

Bachelor of Engineering (B.Tech) in Mechanical Engineering, IP University, Delhi, India.

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