Quality Engineer Design

KAMALUDDIN AHMED

**** ********* ***** *****: 563-***-****

Asbury IA 52002 *********@*****.***

CAREER SUMMARY

Product development engineer with extensive experience in the automotive and heavy equipment manufacturing industry. Accomplished in the design of transmission sensors, park part components, axle pinion gears, clutches, shift systems and internal hydraulic systems. Broad experience in resolving manufacturing issues related to quality and design, applying root cause analysis to design, quality or manufacturing issues and improving supplier manufacturing and quality processes. Dedicated problem solver with strong analytical capabilities. Team oriented leader committed to delivering quality results. Excellent interpersonal, verbal and written communication skills.

Expertise includes:

FMEAs, GD&T, Tolerance Stack Six Sigma Green Belt Certified

DMAIC, SPC, Gage R&R DOE, Root Cause Analysis, Global 8D

FEA, ADAMS Analysis APQP, QS9000/TS-16949

PROFESSIONAL EXPERIENCE

John Deere Construction & Forestry Division, Dubuque, IA 2011-Present

Global Manufacturer for Machinery, Construction & Agricultural

OFP Quality Engineer (February 2020-present)

Support OFP Product Line Programs - investigate manufacturing related quality problems and coordinate issue containment actions with Assembly Operations and/or the supplier. In addition, delivering following tasks.

Investigate quality issues related to product and processes, gather and analyze data to determine root cause, document in NCCA system, and implement corrective action

Use quality tools and practices to establish approval criteria to ensure the identification of quality concerns

Monitor and facilitate quality activities for part approval, verify manufacturing processes and confirm process capability

Generate quality related reports for monitoring metrics

Provide work direction to inspectors and auditors on containment, quality procedures and tools to monitor critical processes

Help to identify Continuous Improvement projects (CI)

PDP Quality Engineer (2011–2020)

Support PDP Product Line Programs

Lead process quality planning activities for new product programs

Work with the Product Development Engineering Group in the development of future product and ensure design for manufacturability

Lead in System, Process and Design Failure Mode & Effect Analysis (FMEA)

Drive problem resolution

Lead inherent reliability and validation

Lead initial reliability verification activities for new product introductions

Execute EETS Reliability Coding Process

Support production start-up and initial field resolution projects for new product

G-TECH, Inc assigned to CATERPILLAR Inc. Aurora, IL 2010-2011

Professional Staffing Company

APQP Engineer

Responsible for APQP deployment activities related to a new product development program.

Executing the design quality aspects of APQP as value added by the product groups. Completing required elements of the APQP/PPAP process, including Boundary Diagrams, P-Diagrams, Interface Analysis, Design FMEA, Special Characteristics, DVP&R, and requirements management using QFD.

FORD MOTOR COMPANY, Livonia, MI 1999-2008

Global automotive manufacturer.

Senior Application Engineer (2007-2008)

Responsible for evaluating customer requirements and determining axle design. Performed design analysis for current axle programs, future products and cost reduction opportunities. Directed CAD designers, manufacturing and process engineers, suppliers, procurement professionals and test engineers.

Saved $647,600 per year by identifying and implementing viable material cost reduction actions for light duty axles.

Developed a new design for the rear axle remote vent hose system that improved differential cover seal weep, improved pinion seal integrity and minimized the wheel seal leaks resulting in better product quality and increased customer satisfaction.

Improved light duty axle durability testing by ensuring road load simulator tests represent realistic road and drive conditions resulting in improved productivity, reduced costs and improved customer satisfaction.

Senior Product Design Engineer (2003-2007)

Responsible for the design, analysis, development and release of front wheel and rear wheel transmission park systems. Managed the park system design, development and validation process from concept thru production launch.

FORD MOTOR COMPANY, (continued)

Re-designed a robust park system for five speed automatic transmissions to prevent unexpected vehicle movement resulting in increased product safety and customer satisfaction.

Re-designed park gear tooth and park pawl geometry to eliminate park pawl hang up issues resulting in increased product safety and customer satisfaction.

Reduced warranty costs by 20% by introducing a 100% hardness strike check for park system components resulting in improved supplier productivity, product safety and customer satisfaction.

Improved customer satisfaction by 30% by resolving shift cable adjustment issues for vehicle no start conditions at the assembly plants.

Saved $521,000 per year by modifying components and qualifying a new supplier for outer manual lever shaft and park pawl shaft for six speed rear wheel drive transmissions.

Applied Six Sigma DMAIC methodology in on-going transmission projects.

Quality Engineer 1999-2003

Managed new transmission range sensor design projects to improve product quality. Prepared all quality documentation and reports to meet customer requirements. Resolved current range sensor issues and improved customer satisfaction and safety performance.

Improved analog positional sensors for low and high mileage performance by 30% by introducing silver contact materials to sensor fabrication.

Improved supplier soldering process for four speed transmission range sensors reducing warranty costs by 20%.

Improved the transmission plant assembly process for range sensor shipping caps by introducing a more robust cap that reduced water intrusion issues.

Qualified a new platter supplier for transmission digital range sensors resulting in improved product quality and customer satisfaction and reduced material costs.

Developed upgraded plating finish for five speed automatic transmissions to resolve durability corrosion issue.

Reduced positional sensor parts returns from the dealers by introducing special processing procedures for the range sensor reducing warranty costs by 30%.

AEROTEK, Inc assigned to General Motors Inc. Flint, MI 1998-1999

Professional Staffing Company

Validation Engineer

Responsible for the design, development, verification and validation testing for new interior door trim and seats.

Collected, analyzed and developed reports to support all validations and product qualifications.

Analyzed program requirements, generated test plans and procured parts needed for verification and validation testing.

Tested interior trim components and systems for validation purposes.

Applied root cause analyses and closed all test incident reports within 90 days.

EDUCATION

MS, Mechanical Engineering, Wayne State University, Detroit, MI 1998

BS, Aeronautical Engineering, Aerospace Institute, Chicago, IL 1983

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