Quality Engineer

THEJA KOMMIREDDI VENKATA SAI

Naperville, IL adjkz6@r.postjobfree.com 315-***-**** www.linkedin.com/in/thejasai Open to Relocation

PROFESSIONAL SUMMARY

4+ years of work experience in Quality Engineering with a Master’s in Mechanical and Aerospace Engineering.

Worked on a wide Product Development and Manufacturing spectrum ranging from High Production Efficiency lines to Early Front End Product Development projects.

Employed various Statistical and Manufacturing targeted Quality Methodologies through multiple projects.

Collaborated with teams in Asia and Europe including China, Taiwan and Germany.

Constantly learning to juggle tight deadlines while producing beyond-expected deliverables.

EDUCATION

Master of Science – Mechanical and Aerospace Engineering May 2016

Syracuse University - Syracuse, New York

Bachelor of Engineering - Mechanical Engineering May 2014

Anna University - Chennai, India

PROFESSIONAL EXPERIENCE

Chervon North America, Naperville, IL July 2018 – Present

Quality Engineer

Roles and Responsibilities

Worked on SKIL, SKILSAW, EGO and FLEX Power Tools.

Actively supported Front End Development of products and worked on the transition to detailed design, tooling builds, manufacturing builds and production build with Product Development Teams in China.

Revised existing test plans, collected data on duty cycles through hand use testing with end users, and drafted new tests to quantitively validate product performance.

Made a successful proposal to management by using Statistical Sampling Methods and Failure Rate Estimations to move away from traditional practices and evolve into employing Statistical Methods for Warranty analysis, which on paper had multi-million-dollar savings potential. The transition project is approved and on-going.

Led Field Test Placement and Data Collection initiatives on multiple projects which involved placement of tools across the country with users in a wide variety of trades in the Home Construction industry.

Designed Warranty Metrics from scratch to provide better exposure on Quality concerns to Management. Followed this up by Owning the tracking of Quality Metrics for multiple brands and providing Monthly reports to Management and Product Development teams.

Performed Monte Carlo Simulations to resolve Tolerance Stack up Issues.

Gained exposure on diagnosis related to Electronic and Battery Components through field failures, in addition to traditional Mechanical Failures that ranging from Motor Failures to impact failures.

Supported the design and validation of test fixture development.

Worked with multiple manufacturing facilities in China and Taiwan to resolve design and production issues.

Visited construction and demolition contractors, and DIY users across the country to understand user application and respond to quality concerns.

Planned and managed QCIs in multiple states with visiting Product Development teams from China.

Employed software including Minitab, Python, and used various Lean Six Sigma and Statistical Quality tools like 8D, 5-Why, Fishbone, Normal Distribution Analysis, etc. on a regular basis.

John Deere, Horicon, WI Mar 2017 – July 2018

Quality Engineer II

Roles and Responsibilities

Supported John Deere Golf and Attachment (Snow Blower, Mower Deck) lines.

Owned Process Failure Mode and Effects Analysis (PFMEA) for Current and Upcoming Model Year Products.

Led Design Process and Assembly Reviews (DPAR) and Capability Studies on running changes and Model Year Programs as a part of PPAP requirements.

Conducted Design of Experiments (DOE) to optimize process parameters.

Created an extensive Quality Plan comprising Capability Analysis, Control Plan and devised Statistical Process Control (SPC) monitoring to qualify a new Blade Forming and Cutting Machine worth $900K.

Analyzed CMM data during Capability Studies in order to qualify parts according to John Deere Standards.

Performed Monte Carlo Simulations, Hypothesis testing, GR&R and employed multiple other statistical tools through various projects.

Followed 8D methodology to investigate and resolve Quality issues in the John Deere Non - Conformance and Corrective Action (NCCA) system.

Worked with the Product Design Group during ‘Design Phase’ of Workflow, to assist them in calling out GD&T requirements that can be met with existing machinery.

Reported monthly to Factory Leadership on Product and Process First Pass Yield (FPY) and Quality Index (QI).

Utilized SAP on a daily basis to manage Quality Hold projects, Deviations and Workflow tasks.

Led Quality Improvement Team (QIT) activities by working with Customer Support, Product Engineers and Manufacturing Engineers.

Engaged with Key Customers and Dealers on multiple occasions to understand issues that were high priority.

Worked with Customer Support Representatives in the Early Detection Problem Resolution (EDPR) Program to identify trends and resolve issues in Warranty Claims.

Acted as a Continuous Improvement (CI) Quality Representative for multiple production departments.

Focused efforts on Poka Yoke (Mistake Proofing) for assembly issues.

Worked with teams from other sister factories within and outside the United States, to perform Quality related activities during Product Development, for the products that would be produced in Horicon Works.

TECHNICAL PROFICIENCY

Statistical and Industrial: SAP, PDM, MATLAB, Minitab, Python, SharePoint, DMAIC, 5S, Lean Manufacturing, JIT, Kanban, FMEA, Continuous Improvement, GD&T, 8D, Lean Six Sigma, Excel.

GRADUATE LEVEL COURSEWORK

Design for Manufacturing

CAD/CAM

Lean Six Sigma

HVAC

Project Management

Advanced Mechanics of Materials

Fluid Dynamics

Principles of Turbomachinery

Applications of CFD

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