Manufacturing Engineer Assembly Line
Resume:
Rahul Surendran Manufacturing Engineer *
adl36k@r.postjobfree.com
linkedin.com/in/rahulsurendr
Kerala, India
1.Profile Summary
Objective: To become a goal oriented and energetic team leader in motivating participants with enthusiasm and encouragement and demonstrate my meticulous administrative skill in manufacturing engineering for personal and company growth
Strengths: Leadership, goal oriented, strong-willed, creative, problem solver, fast learner
●M.E. (Tool Design) with 4 years of experience in supporting Product Development, New Product Introduction and Quality Assurance
●Hands-on experience in assisting suppliers in design, development and commissioning of Large Assembly lines, fixtures, Mould and Press Tools
●Strong abilities in creating/ reading/ interpreting engineering drawings
●Proven skills in enhancing production process and quality, optimizing resource & capacity utilization while curtailing costs & expenses
●Excelled at delivering projects following APQP & PPAP guidelines and productivity improvements through Lean Manufacturing
●Possess excellent communication, relationship management, team building and analytical skills
2.Academic Detail
Year
Degree
Institution
Grade
2016
M.E. Tool Design
Central Institute of Tool Design (Osmania University), Hyderabad
CGPA 7.60
2013
B.E. Mechanical
Sona College of Technology (Anna University), Salem
CGPA 8.12
2009
HSE
Jawahar Navodaya Vidyalaya, Kannur
% 82.80
3.Skill Set
Tooling & Machine Development
New Product Development
Process Improvement
Operation Management
Quality Control & Assurance
Auditing & Compliance
Risk Management
Lean Manufacturing
Six Sigma Methodology
Stakeholder Engagement
CAD/CAE software’s & SAP
Training
4.Certification & Training
Year
Certificate
Abbreviation
Institute
2021
Line Balancing – Timer pro professional (no certification)
Timer Pro
ACSCO
2020
Lean Six Sigma Black Belt
LSSBB
HCG Int.
2020
Design and Development of Medical Devices
ISO 13485:2016
Udemy
2020
Medical Device Risk Management
ISO 14971:2007
Udemy
2018
Safety Management Auditing Technique
SMAT
Whirlpool
2018
Certified QMS Internal Auditor
ISO 9001: 2015
DQS India
5.Work Experience
S. No
Organisation
Responsibility
1
Whirlpool of India, Pondicherry
*
(Jan’17 Sept’19)
*
Senior Tooling Engineer
(senior executive)
*
Division Process Engineering
*
Business Washing Machine
1.Developing, analysing and managing Manufacturing/ Assembly/ Automation Projects.
2.Engaging in creative problem solving to address operational issues including: ergonomic/ safety, efficiency improvements, process bottlenecks, quality concerns.
3.Manage projects to ensure efficient and cost-effective systems and processes to produce quality products.
4.Providing the application, procurement, processing, installation and capability for new equipment.
5.Providing manufacturing technical support in process control and internal certification.
6.Coordinating the purchase and application of machine tools, controls and related equipment to ensure the latest technology is being used to increase efficiency and economy of operations.
7.Implementing projects with standard APQP process, process flow, Layout design, PFMEA, control plan, work instruction and checklist.
8.Evaluate projects and prepare feasibility studies to define desired results, assess value proposition and determine project plans.
9.Improve space utilization in the shop floor.
10.Develop and implement assembly processes in line with Whirlpool standard processes.
11.Designing/ Develop tools and fixtures.
2
Rane Die Cast Limited,
Hyderabad
(May’16 Oct’16)
Manufacturing - Intern
Division Manufacturing
Business Automobile Pressure Die Casting parts
1.Die Design Kaizen & documentation (PTC Creo)
2.Casting flow analysing (Software – Adstefan)
3.Casting defects data collection
4.PPAP documentation support
3
Hyderabad Dies & Molds, Hyderabad
(Nov’15 Apr’16)
Tool Designer - Intern
Business Tooling design & Manufacturing
1.Injection Mould designing (Unigraphics NX)
2.Mould flow analysing (Software - Autodesk Moldflow)
3.Mould matching & trial
6.Reward & Recognition
Year
Award
Category
Organisation
2012
1st prize, National level
Best Computer Aided Engineering Report for Supra racing car competition (Role –Author, CAE Lead)
SAE India
2011
2nd prize, International level
Sustainable product design contest (educational catg.)
Solidworks Corp.
7.Reference
S. No
Personnel
Professional Detail
Contact Detail
1
Mr. Rajesh Ranjan
Six Sigma Coach,
HCG International
adl36k@r.postjobfree.com
2
Mr. K J Idhayachandar
Ex - Process & projects lead, GM-Production, Whirlpool Puducherry
+91-924*******, adl36k@r.postjobfree.com
3
Mr. Paresh Kumar Panigrahi
Manager Manuf. Engg.,
Ex-Rane group(now-BFL)
Whirlpool Career Assignment in Detail
A.Problem Solving
Year
Problem Solved
Approach
Savings/ Year
2019
Reduction of Basket production rejections by 12%
PDSA
(Ishikawa diagram/ Kaizen - Poke-Yoke)
60.17 L
2018
Reduction of Cabinet Emboss Press Tool rejections by 14.5%
PDSA
(CAPA / Tooling correction)
72.2 L
2017
Reduction of drive insertion equipment rejections by 25%
DMAIC
(R&R/ Tooling correction/ SPC monitoring)
83.4 L
B.New Product Initroduction
Year
Project Type
Task
Highlight
2019
Top Load FA washing machine (Invertor - stain wash)
Process Flow Chart
Work Study (Method/ Cycle time)
PFMEA
Make vs Buy (identification, costing)
Work Instruction
Quality plan documents – Control Plan, In-Process-Verification-Plan, SMT Checklist
Nut runner & fixture facilitation
Work facility & Material handling
Low Cost Automation
Ensured first time right
Matched with regular productivity
2018
Top Load FA washing machine (stain wash)
Handled 30L on assembly line facilitation
2018
Kitting - Semi-Automatic w/m to South Africa
Process flow established with 70% of regular productivity
2017
Semi-Automatic w/m (Ace XL, Turbo dry)
Handled 15L on assembly line facilitation
C.
C.Process Gap Analysis & Improvement
Year
Project Type
Approach
Benefit
2018 – ‘19
Space utilization improvement at Packaging Area line 1
5S & JIT
(Layout change, Mezzanine floor, Assembly line extension)
Achieved 200%
2018
Productivity improvement at Top Load assembly line 2
5S & VSM
(Layout change, 8 waste elimination, out sourcing, LCA, Work balancing by Yamazumi)
Achieved 5%
Assembly line HC reduction 4%
2017 – ‘18
Productivity improvement at line 1 (Semi-automatic washing machine assembly line)
Achieved 14%
Assembly line HC reduction11%
Achieved record-breaking monthly production 1.5L
2017 – ‘19
Engineering change order
Documentation, facilitation, Quality assurance
53+ nos.
2017 – ‘19
Safety improvement
Kaizen
20+ nos.
D.COPQ Improvement
Year
Project Type
Approach
Benefit
2019
Finished Goods packaging
Preload-SPM implemented
Field strap failures 21%
2019
Motor to motor plate fastening assembly
Ergonomics improved/ New SMD-fixture/ Poke-Yoke by Electric Nut Runner
Assembly miss 1.5% and 100% SPC monitoring
2018
Motor pulley Nut fastening
New pulley / New Torque/ Ergonomics improved / SMD-fixture
Nut unfastening field failures 9.25%
E.Machine Development & Commissioning
Year
Machine
Tasks
Supplier
Cost
2019
Basket Grooving m/c
RFQ preparation
Design Verification of product & machine
Pre-acceptance checklist
Export/ Import doc handling
Stake holder Engagement
PPAP
PFMEA, Aspect-Impact, HIRA
Operator Training
Quality planning documents
Troubleshooting visits Support
Plantech, South Korea
0.11 M$
2018
Semi-Automatic Basket production m/c
Moss Alliance, Italy
2.35 M$
2018
Automatic Cabinet production m/c
Hana-Gns, S. Korea
2.88 M$
2017
Energy and Water Calibrating Test Rig m/c
Shikar Automation, Faridabad &
Mirhae Engineering, Pune
35L
2017 - ‘19
Weighing bridge 16x3, VVVF Panel 60/50, Genset 600, Compressor 300, Conveyor, Oil chiller 14KW
RFQ preparation, sourcing support
Utility Installation & Commissioning
1.28Cr
F.Audit & Compliance
Year
Internal Audit
Audited Function
2019
ISO 9001
Technology Centre
2018
ISO 9001
Human Resource Department
2018 - ‘19
Safety (SMAT)
Shop floor, JIT Bay, Hydrant Room
Revised Date: 26 Apr 2021 Faithfully, Rahul Surendran…
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