Saiteja Nalla

**** **** **, ******, **, ***** • +1-906-***-**** • adjdyz@r.postjobfree.com

SUMMARY

Adaptable and responsible Mechanical Engineer with 3.5 years in manufacturing, CNC machining and an M.S. in mechanical engineering, seeking a mid-level or entry-level manufacturing position. Experienced professional in Lean manufacturing and Six Sigma with strong communication and presentation skills.

EDUCATION

Michigan Technological University Houghton, MI

Master of Science, Mechanical Engineering. GPA: 3.5/4.0 May 2020

• Head of Mind Trekkers Club, involving traveling to different schools across the U.S. to deliver high-energy, hands-on STEM demonstrations to K-12 students, inspiring them to pursue post-secondary education. Jawaharlal Nehru Technological University Hyderabad, India Bachelor of Technology, Mechanical Engineering. GPA: 4.0/4.0 May 2016

• Won 1st prize in national technical paper presentation competition on Kinetic Energy Recovery Systems, hosted by SAE India.

• Won gold medal for outstanding academic performance.

• State Under-21 Badminton doubles champion

EXPERIENCE

Seagrave Fire Apparatus Clintonville, WI

Manufacturing Engineer Co-Op May 2019 – Apr. 2020

• Engineered workstation design with visual controls, workbench, and efficient material movement at robotic welding station and CNC workstation, structuring workstation to comply with Lean and OSHA safety standards.

• Wrote CNC and Robotic Programming, PLC Controls Programming for the Automated process, Helped in savings of $80k by reducing the steps and decreasing the idle time by following Lean JIT principles

• Analyzed SPC charts to determine causes of process variation and drive root cause analysis using 8D and 5Why problem-solving techniques, reducing scrap by 28% by implementing Six Sigma Techniques in the Machining Area.

• Developed 2D & 3D Drawings & Layouts as per (GD&T) and industry standards. Reviewed Engineering Change Notices (ECN).

• Performed Routing for various Machining Parts in Oracle ERP system, effectively routed 200 plus new parts to the system.

• Utilized bi-weekly Kaizen events to brainstorm on ways to improve process documentation in the CNC and assembly areas, reducing manufacturing time and increasing work efficiency and safety protocols.

• Performed 5S on entire Machine shop and standardized documents/check lists, reducing the lead time of the ladder by 30%.

• Developed and maintained safe work environment by complying with SOPs, ECN, ECR and performing fixturing and documentation.

• Implemented a hybrid automated solution for Miller robotic welding operations, resulting in 90% robotic welding and 10% manual welding and increasing production efficiency between 15-20%.

• Resolved “ship-loose” problems by standardizing process and performing root cause analysis on issues and gaps in production times. Indy Engineering Hyderabad, India

Manufacturing Engineer Jan. 2016 – Jun. 2018

• Implemented balanced assembly line using Lean Six Sigma methodology, improving overall work efficiency.

• Analyzed SPC charts to establish process control around key manufacturing processes and revised sampling strategies based on defect escape rate, reducing defect escape rate by 8%.

• Established Kanban System for the gear machining process, initiating a pull system which increased productivity by 25%.

• Initiated various Kaizen events all over the fabrication plant, increasing the efficiency by 18%.

• Supported the improvement of company curriculum by providing various levels of end user and training classes, instilling employees with a comprehensive understanding of specific material and processes.

• Designed and implemented new Lean metal stamping station with 90% automation and 10% manual input and wrote programs for the robotic arm, troubleshooting as needed for efficiency and reducing program times by 20%.

• Established KPIs, focusing on the core improvement objectives that complied with company standards.

• Directed team of 3 on projects to improve safety and quality, reduce cost, and improve schedule performance.

• Reduced material and handling cost and improved throughput using ERP systems, saving $150k per quarter.

• Lead a team of 4 people to design process plans and standardize work instructions, working with various departments of the organization including operations and quality control to ensure timely deliverables. Nuclear Fuel Complex Hyderabad, India

Design Engineer Intern May 2015 – Aug. 2015

• Designed fixtures for electron beam welding machine, ensuring its compliance with DFM/DFA principles.

• Envisioned welding machine with the capacity to weld 12-ft.-long tubes and developed model using SolidWorks, optimizing work performance and productivity.

• Replaced old gear drive with belt drive and placed a spring mechanism at the tail end of machinery, improving the accuracy of the fit and enhancing quality by 40%.

ACADEMIC PROJECTS

Michigan Technological University Houghton, MI

Design of Dams to Reduce Massive Floods Jun. 2020 – June 2021

• Envisioned an efficient, electric-powered Treadle pump in compliance with DFM/DFA principles and 3D printed the model to study the form, fit and function of the product.

• Tested 3D printing on 1:3000 scale, generating insights into how solutions to massive flooding can be manufactured in dams. Design Optimization of Hybrid Aluminum/Epoxy Carbon Prepreg using FEA Aug. 2019 – Dec. 2019

• Designed a Hybrid shaft using Aluminum 6061-T6 Alloy and performed FEA for 256 different orientations of Epoxy Carbon prepreg UD using Ansys 18 to determine the best orientation.

• Collaborated with a team of 3 to analyze data using Minitab, determining optimal orientation by comparing total deformation, critical buckling torque and frequency.

Prototype Development using Additive Manufacturing Technology (AMT-Plastic) Jan. 2019 – Mar. 2019

• Designed CAD, manual brake press prototype using DFM/DFA principles and 3D printing to study the form, fit and function of product.

• Tested the 3D printed model using the additive manufacturing process, determining reliability, durability and cost-efficiency for developing 3D prototypes.

Structural and Interior Engineering, Super Mileage Enterprise Aug. 2018 – Dec. 2019

• Designed a roll cage for static and dynamic loading, developing mounting points for efficient packaging of subsystems.

• Engineered a frame chassis model and used Minitab to perform FEA, optimizing the diameter to 26.4 mm.

• Collaborated with transmission team to design engine mounts, brackets, propulsion shafts, bumpers and driver seat mounts, reducing project-building time by 20% when compared to the last 2 years. Statistical Analysis using DOE Aug. 2018 – Dec. 2018

• Collected the real-time drive cycle data for 4 different vehicles to calculate optimal fuel efficiency.

• Analyzed data using statistical DOE tools such as ANOVA and factorial design in Minitab, determining the operating levels for a multi- factor, multi-level objective in obtaining optimal fuel efficiency. PROFESSIONAL SKILLS

Technical: Solid works, CAD, FEA, ANSYS, Abaqus, PLM, GD&T, Minitab, CATIA, PTC Creo, DFMEA, PFMEA, DFSS, PPAP, 5S, DMAIC, ERP, BOM, DVPR, MATLAB, Minitab, 3D Printing and MS Office. Core Competencies: Product Life Cycle, Six Sigma, Root Cause Analysis, Tolerance, Stack up and Vehicle Dynamics. Certifications: Lean Six Sigma Green Belt (MSI 2019), Engineering in Training (EIT) certification (2019).

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