Engineer Design
Resume:
THIRU PANDRANGI
Email: adgli3@r.postjobfree.com
Phone: 248-***-**** ©
Objective:
A dynamic professional over 20 plus years of rich & extensive in project delivery, thoroughly involved in team leading on designing, testing, validating mechanical /hydraulic fuel injection systems and fuel pumps. involving excellent cross functional interaction with Design, Assembly, Operations, Testing, Manufacturing & System Controls.
Skills
Pro E Wildfire, MS Office, Microsoft Project, MS Excel, HVC, Catia v5, Minitab, AutoCAD, WERS, Adobe Photoshop, Kronos, Kronos Timekeeping, Weibull analysis
Education:
MS Mechanical Engineering, WMU, Kalamazoo, Michigan. December 1993
BS Manufacturing Engineering, Andhra University, India December 1989
Personal: U. S. Citizen
Work Experience: Key responsibilities as a senior design engineer is to lead designing, releasing, product development, manufacturing, system integration & testing, quality improvements, manufacturing and warranty.
Senior Product Design & Release Engineer: May 2008- Oct 2020
Involved in creating solid models and prints of prototype parts for design and analysis using Pro E.
Conceptual phase to Production experience in New Product Introduction.
Product lead on MEUI/HEUI products, FMEA, DVP&R and design reviews.
Responsible for product development, and compliance with APQP processes and product PPAP submission and approval requirements.
Chaired first test pass, DFMEA and DVVP&R, GD&T, Root Cause analysis sessions.
Responsible for CPI (Continuous product Improvement) for components,
Six Sigma Green belt (team member in projects) 1.5million in savings; Responsible for end of line spec development and production support of K-Factor injector products at Caterpillar Pontiac Fuel systems.
Engineering planning and design, fabrication, establishing safety protocols, installation, system integration, commissioning, organizing and scheduling safety reviews and design reviews, and ensuring quality assurance standards for every engine test cell installation
Prototype parts order and procurement for testing.
Experience working with Cat industry representatives, dealers and customers to understand voice, document requirements, resolve issues and/or communicate updates.
Strong accountability, teamwork, and interpersonal skills, and communication skills.
Working on identifying and implementing cost reduction activities for the EI-800 injector.
Provided technical assistance during NPI, resolved quality issue on the floor.
Coordinate and organize team meetings to update the work in progress and to set future goals to meet the project timeline.
Product Development / Manufacturing Engineer: May 2008- Oct 2020
Lead CPS improvement activities and bench marking studies to determine best practices/design.
Wrote reports and presented progress in leadership meetings.
Experienced in Lean manufacturing, reduced waste and downtime.
Leading product Design for manufacturability and sustainability including GD&T analysis, Doe’s development, FMEA/PFMEA, “critical to quality parameter”, experienced in APQP, SPC, control plans, PPAP, 8D’s, NPI and CPI.
Supported Ergonomic process of designing products, systems and devices so that they fit the people that use them to minimize the risk of injury or harm (Ex. Torque wrenches, screw drivers, hand tools).
Ergonomically avoiding high task repetition, forceful exertions, repetitive/ sustained from awkward positions. The aim is to create a comfortable, safe and productive workspace by bringing together health and design, with positioning and adjustments.
Experienced in plant layouts using AutoCAD and facility engineering.
Coordinated activities in scrap reduction, elimination of rework parts, material and labor variances.
Served and experience in stamping facility as point of contact to local vendors and suppliers.
Documentation of product requirements for equipment specifications.
Leading product design for manufacturability and sustainability including:
o
GD&T analyses
o
DOEs
o
Development of FMEA/PFMEA, “critical-to-quality” parameters
o
Development of specifications for preventative and detection methods
o
Process testing and validation
o
Documentation of product requirements for equipment specification
•
Process development for early concept and early prototype production through to start of production +90
o
Technology research and development in design and manufacturing
o
Process invention, development, trials, and testing that shape the design of the product
o
Process release through detailed manufacturing instructions, workstation and line layouts, product trials, and
prototype production management
•
Factory design, layout, and simulation for:
o
Line balancing
o
Capacity simulation and modeling
o
Part and assembly presentation
o
Specification of hand tools for manual assembly tasks
o
Data systems
o
Yield studies
•
Product launch and process validation
o
Draft qualification protocols and manage process qualification activities.
o
Lead and provide process validation/qualification documentation
o
Utilize statistical tools (such as GR&R, SPC and Cp/pCk) to ensure processes/fixtures are performing
•
Coordination with other process, equipment, mechanical, electrical and support disciplines including project
managers, manufacturing reps, and other stakeholders.
Leading product design for manufacturability and sustainability including:
o
GD&T analyses
o
DOEs
o
Development of FMEA/PFMEA, “critical-to-quality” parameters
o
Development of specifications for preventative and detection methods
o
Process testing and validation
o
Documentation of product requirements for equipment specification
•
Process development for early concept and early prototype production through to start of production +90
o
Technology research and development in design and manufacturing
o
Process invention, development, trials, and testing that shape the design of the product
o
Process release through detailed manufacturing instructions, workstation and line layouts, product trials, and
prototype production management
•
Factory design, layout, and simulation for:
o
Line balancing
o
Capacity simulation and modeling
o
Part and assembly presentation
o
Specification of hand tools for manual assembly tasks
o
Data systems
o
Yield studies
•
Product launch and process validation
o
Draft qualification protocols and manage process qualification activities.
o
Lead and provide process validation/qualification documentation
o
Utilize statistical tools (such as GR&R, SPC and Cp/pCk) to ensure processes/fixtures are performing
•
Coordination with other process, equipment, mechanical, electrical and support disciplines including project
managers, manufacturing reps, and other stakeholders.
Leading product design for manufacturability and sustainability including:
o
GD&T analyses
o
DOEs
o
Development of FMEA/PFMEA, “critical-to-quality” parameters
o
Development of specifications for preventative and detection methods
o
Process testing and validation
o
Documentation of product requirements for equipment specification
•
Process development for early concept and early prototype production through to start of production +90
o
Technology research and development in design and manufacturing
o
Process invention, development, trials, and testing that shape the design of the product
o
Process release through detailed manufacturing instructions, workstation and line layouts, product trials, and
prototype production management
•
Factory design, layout, and simulation for:
o
Line balancing
o
Capacity simulation and modeling
o
Part and assembly presentation
o
Specification of hand tools for manual assembly tasks
o
Data systems
o
Yield studies
•
Product launch and process validation
o
Draft qualification protocols and manage process qualification activities.
o
Lead and provide process validation/qualification documentation
o
Utilize statistical tools (such as GR&R, SPC and Cp/pCk) to ensure processes/fixtures are performing
•
Coordination with other process, equipment, mechanical, electrical and support disciplines including project
managers, manufacturing reps, and other stakeholders
Leading product design for manufacturability and sustainability including:
o
GD&T analyses
o
DOEs
o
Development of FMEA/PFMEA, “critical-to-quality” parameters
o
Development of specifications for preventative and detection methods
o
Process testing and validation
o
Documentation of product requirements for equipment specification
•
Process development for early concept and early prototype production through to start of production +90
o
Technology research and development in design and manufacturing
o
Process invention, development, trials, and testing that shape the design of the product
o
Process release through detailed manufacturing instructions, workstation and line layouts, product trials, and
prototype production management
•
Factory design, layout, and simulation for:
o
Line balancing
o
Capacity simulation and modeling
o
Part and assembly presentation
o
Specification of hand tools for manual assembly tasks
o
Data systems
o
Yield studies
•
Product launch and process validation
o
Draft qualification protocols and manage process qualification activities.
o
Lead and provide process validation/qualification documentation
o
Utilize statistical tools (such as GR&R, SPC and Cp/pCk) to ensure processes/fixtures are performing
•
Coordination with other process, equipment, mechanical, electrical and support disciplines including project
managers, manufacturing reps, and other stakeholders
Process Development of early concept and early prototype production thru start of production.
Worked on time study process determining most efficient amount of time to spend on a particular phase of the manufacturing process, then work sampling is one of the most effective tools to help this process.
Participated in engineering design reviews to assist with design for manufacturability.
Provided support to maintenance department to develop detailed instructions for preventive and predictive maintenance tasks for the equipment.
Manage process activities, Lead and provide process validation. Utilizes statistical tools such as Gage R&R, SPC, CPK studies to ensure processes fixtures performing.
Factory design, layout and simulation for line balancing, capacity simulation and modeling, part and assembly presentation, specification of hand tools for manual assembly and yield studies.
Product launch and process validation.
Coordinate with other process equipment, mechanical and electrical and support disciplines including project managers, manufacturing rep, and other stake holders.
Developed processes and tooling requirements to meet customer specifications.
Optimized product flow and line efficiency by designing or improving tools, jigs, stations, work methods and ergonomics using the 5S methodology.
Recommended purchasing new equipment, systems and facilities to reduce manufacturing costs and meet strategic business plan.
Supported lean manufacturing activities throughout manufacturing facility.
Quality Engineering: May 2008- Oct 2020
Identifies and implements safety and ergonomic improvements.
Facilitated and escalated unresolved quality issues within assigned projects and suppliers.
Project lead within operations engineering and design engineering
Performed on-site supplier visits for root cause analysis and verified on supplier quality issues on tappet springs, plungers, valve’s, solenoids etc.
Committed to quality by striving for reliability and quality on injector components
Schedule meetings with suppliers and find root cause analysis and corrective actions of supplier on quality concerns.
Verify incoming quality parts for dimensional per SPC, metallurgy Implementing and part qualification and certification processes (PPAP, Run at Rate).
Develop requests for fiscal capital budget in conjunction with shop management
System Integration Test Engineer: May 2008- Oct 2020
Supporting in developing and updating test strategy, bench testing, lab and planning
Achieve cost, quality and schedule initiatives in compliance with the Continental development process and general automotive standards
Create System Integration Test Report.
Design, develop, and implement cost effective methods of system integration testing.
Perform and lead complex system integration tasks and problem solving under the limited supervision of senior engineering staff.
Analysis, documentation, discussion and tracking of test results.
Failure analysis and troubleshooting.
Create an excellent working relationship with engineering group and management.
Responsible to support EBT (Electronic Build Test) engineering work, test & development team.
Support for testing of new products, and changes to existing products.
Work with engineering leads to employ iterative development test strategies and tactics on assigned projects and ensure full execution of the strategy.
Perform business and system analysis; provide recommendations for process improvement.
Monitor and improve productivity through the use of Lean Six Sigma or related tools, while ensuring all customer commitments are met in a timely, quality and cost-conscious manner
Warranty /Quality Support: May 2008- Oct 2020
Analyze warranty data & dealer verbatim, provides team with timely identification of warranty trend/concerns.
Provide field quality report (Pareto charts, Trend analysis and RWA).
Warranty part retrofit & dealership visit as required
Engineering support to analyze, resolve and take corrective measures to address field issues, warranty analysis and failures.
Champion of Interior/Exterior parts warranty cost reduction
Create technical report to summarize field issues, fail modes & root causes to determine appropriate % of TG responsibility contributed to the field issues
Presentation & negotiation the appropriate TG warranty cost share rate with the Customers
Participates warranty reviews at customer warranty review centers, manages warranty projects initiated by OEM customers.
Initiates root cause investigation using appropriate OEM problem solving methodologies Create “warranty lessons learned" actions taken as a design group Team Lead
Participating in creating design solutions to address warranty issues.
Good understanding of feature inspection and measurement equipment.
Design & Release Engineer Ford Motor Company, Dearborn, Michigan 12/2001 – 6/2008
Major Responsibilities:
Design Engineer of chassis components, including parking brakes, foundation brakes, calipers, wheels, and tires, design and development of validation of actuation brake components (including Brake Booster, Master Cylinder and Park brake). TPMS Sensor for S197 (Mustang) and C170 (Focus).
Design reviews and clearance checks with program management and customers.
Experienced working with Instrument panels, fascia, hood, interior door panels, seating, lighting and material handling equipment’s
Worked on time study process determining most efficient amount of time to spend on a particular phase of the manufacturing process, then work sampling is one of the most effective tools to help this process.
Significant digital creation, evaluation and compatibility process knowledge using C3P NG tools (Catia V5, Checker and Digital Buck/DMU).
Works with studio engineers, modelers, other designers, and service and fabrication personnel in the development of new ideas in both 2D and 3D three-dimensional form
Assisting Design and Release engineers creating design documentation such as detailed product component and assembly drawings and bill of materials to send to suppliers to be able to construct engineering mark-ups
Work with Packaging Engineering group to guide and assist in testing, assembly and installation of the designed systems.
Coordination with other designers and Release Engineers to learn quickly.
Lead Design and GD& T expertise to release parts thru PPM audit for Radiators, tubes, hoses, Exhaust Pipes.
Liaison with release engineers, process engineers and conducted design review meetings and presented new product design packaging study stacks which includes new design proposals, testing components, DFMEA, PPAP and communicate with suppliers.
Supported engineering &program disciplines including Bill of materials, P-diagram, DFMEA, PPAP, 8D's and warranty issues.
Supported product launch and lead the manufacturing interferences with the supplier and Assembly plants.
Experience with Ford systems (WERS/BOM’s/GPIRS/DFMEA/8D's/etc.).
Managed three Phase Geometric Dimensioning and tolerances (GD&T) meetings and resolve many issues with the supplier before the P-Authority.
Competitive vehicle benchmarking, target setting and target compatibility for new products
Strong written and oral communications skills. Excellent people and organization skills and be able to work hard in a rapid paced environment.
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