Engineering Consultant Quality Engineer
Resume:
VIJAYA KUMAR PILLY
**** *********** ***, ******** *******, CA
Cell : (626) 482- 0753
E-Mail: ******@***.***
http://www.linkedin.com/vijayapilly
Engineering Career Summary:
●An Accomplished, HANDS - ON Results Oriented Electronics Hardware Quality Engineer with a Proven Track Record of Technical Achievements and Product Cost Savings within Aerospace, Commercial and Bio-Medical Industries.
●Pro-active
●Worked on Multiple Engineering Roles within New Product Introductions (NPI) Manufacturing, Test, Quality, and Customer (RMA) Departments. Experienced working with FAA /EASA Repair personnel.
●Supported U.S. Army, Navy, and Air Force.
●Worked on Several NASA Space Programs (Space Station Freedom ISS with Rockwell, Falcon 9 with SpaceX, Mars 2020 Range Rover for JPL, SLS, ARTEMIS with Teledyne Technologies)
●A Passion for Solving Product / Process Problems and working towards full End Customer Satisfaction.
●PPM reductions
●Proven Technical Problem Solver
●MRB Inventory and Scrap Reductions
●Saved over ($35M$) in Product / Process Improvement costs by implementing Lean & Six Sigma Techniques working in Commercial, Aerospace, and Bio-Medical Industries for over (35) years.
●U.S. Citizen with an Inactive Department of Defense (DOD) Secret Clearance.
●Active National Agency Check (NACI) clearance issued by/for JPL (Jet Propulsion Labs), Pasadena, CA.
●Reduced Product Costs and Improved Product Quality by conducting the Root Cause Analysis of Manufacturing, Test, Component, and Design Issues and implementing the recommended Corrective and Preventative Actions.
●Extensive use of Lean Techniques, Six-Sigma Methodologies, and other TQM Tools.
●Proven Project / Program / People Management Skills.
●An Integrated Product Team (IPT) Leader and a Team Player.
●Supplier / Product Quality Development / Management.
●Worked with (8) Electronics Contract Manufacturers built to print packages (Sanmina - SCI, Solectron, Celestica, Plexus, Cal Quality Electronics, Kimball Electronics, OSI Electronics, Rockwell Mexicali EMS) for both Domestic and International PCBA, Cable Manufacturing.
●Worked with AS9100D, ISO 9001, ISO 13485, TS 16946, NASA 8759S, TL 9000, BOEING D1- 9000, MIL-STD 883, ITAR Specs. ERP, MRP, SAP
●University Teaching / Industrial Training Summary:
●Over (15) years of teaching Electronics Courses as an Adjunct Professor @
●Cal Poly University, Devry University, ITT Technical Institutes, and Mt.Sac Jr College)
●Over (25) years of conducting Company Training Classes for the Test, Manufacturing, and Quality Teams within the Commercial and Aerospace Electronics Industries.
●Member of Academic Advisory Boards at Mt Sac Jr. College and ITT Technical Institutes, CA.
●McGraw-Hill Text-Book Editing. Curriculum Developer
Sr. Quality Engineering Specialist
Stellant Systems, Inc, Torrance, California, United States
Jan 2022 – June 2022
●Supporting Hardware Quality Engineering functions in the manufacturing of Microwave Power modules (MPM), Travelling Wave tubes (TWT), and various RF and Microwave Components supporting Space Manufacturing Labs.
●Working with Contract Manufacturing (EMS) Suppliers in Built Print PCBAs per Data Packages.
●Member of Root Cause and Corrective Action Board (RCCAB).
●Supporting (Non-Conforming Material reports (NCMR) activities and resolutions.
●Supporting Material Procurement Group in purchasing activities and Alternate part replacements.
●Working with Multi-Disciplinary Teams in solving Product Quality issues and reducing Overall Product Costs.
●Working together to reach ZERO DEFECTS and 100% CUSTOMER SATISFACTION.
H.W.Quality Engineer IV / Site Q.E. @ AMRO Corp. (Launch Vehicle Stage Adapter, NASA, MSFC, Alabama)
AMRO FABRICATING CORPORATION, South El Monte, CA
Jan 2019 - Oct 2021
●Performed On-Site Quality Engineering Support functions @ AMRO Corporation, South El Monte, CA on Launch Vehicle Stage Adapter Structures (LVSA) for Teledyne Brown Engineering (TBE), Huntsville, AL. on Artemis Program with Mission to Moon.
●Reviewed and Approved
●Statement of Work (SOW}, Manufacturing Planning Route Sheets and the Process/Program execution on Gantry Milling Machines.
●Also Monitored and Approved the Machining, Laser Inspection, Eddy Current, and Fracture Toughness test reports along with First Article reports (FAI) on the Aluminium - Lithium FWD and AFT Panels per the GD &T ANSI-Y14.5-2008.
●Generated Non-Conformances (NCR) on any observed deviations in the product specifications during the entire Fabrication and Forming process. Requested for the Root cause and Corrective actions (RCCA) from the Supplier to prevent any future non-conformances.
●Supported the manufacturing (Machining & Forming) and NDT (Non-Destructive Testing) of the Mechanical Structures (FWD and AFT Panels), Confidence Weld Panels, and Rings from the start to finish (Full Life Cycle) to be delivered to TBE and then to the end customer (NASA Marshall Space Flight Center, Alabama) for all Spacecraft Launch Systems (SLS).
●Reviewed NDT Reports on chemical etching, deep penetration, radiological testing, and ultrasonic testing
●Worked with DCAS personnel
●Worked on castings and mechanical aerospace components
●Supported and monitored outside NDT processes (Chemical Etching, Deep Penetration} with Morrell's Aerospace, CA for Teledyne Technologies (TBE).
●Interfaced with DCMA / NASA personnel in the approval process on the Space Flight Hardware buy-off both @ AMRO and they're outside Second Tier Suppliers. Also supported and monitored Material Fracture Toughness tests at the outside test labs (Element Technology, CA).
Hardware Quality Engineering Consultant
Vantage Associates (Aerospace Company), Santa Fe Springs, CA
Nov 2018 - Dec 2020o-forming Aircraft
●Interior components for BOEING, Zodiac Aerospace, and Cessna Aircraft. Supporting ULA, DFAS.
●•Supported NCR, RCCA, and MRB Inventory Reductions.
●Quality Engineering Support for the manufacturer of Composites, Laminates, ThermSr.
●Continuous Improvement in Processes
●for better Product Quality and reduced overall Product costs and maximized Customer Satisfaction.
●EPICORE (ERP) tool and BOEING Supplier Base RCCA web-based tools.
Sr. Space Hardware Quality Engineer
Jet Propulsion Labs (JPL) @ California Institute of Technology, Mars Rover 2020 · Contract
Feb 2018 - Apr 2018 ·
Pasadena, CA
●Supported Flight Hardware Functional Tests in Mars 2020 Rover Space Labs (MSL)
●Supported Ground Support Equipment Cable assays testing using Cirris Plus Systems
●Supported Thermal Painting Shop for painting Mechanical Hardware for Sentinel, M2020 Programs.
●Worked and approved IBATs, IRs for closure. Worked per NASA 8759S specifications.
●Quality buy-offs on Mechanical Truss Support Structures on Torquing for SWOT program for BOEING.
●Supported the quality buy-off for the Space Flight Hardware and Cable Assemblies for Range Rover Mars 2020 Project
●Also supported the Mechanical Robotic Components and Structures.
Supplier Quality Engineering Consultant
Medtronic
Jun 2017 - Jul 2017
Irvine, CA
●Supported Supplier Change requests (SCR), Non-Conformances (NCR), and Supplier Score Card tracking. MRB resolutions,
●Supplier Audits and Continuous Process Improvements.
●Developed, modified, applied, and maintained quality standards and protocol for processing materials into partially finished or finished materials products.
● Devised and implemented methods and procedures for inspecting, testing, and evaluating the precision and accuracy of products and production equipment.
● Designed and specified inspection and testing mechanisms and equipment; conduct quality assurance tests and performed statistical analysis to assess the cost of and determine the responsibility for products or materials that do not meet required standards and specifications. Ensured that corrective measures meet acceptable solutions
● Worked with design, incoming material, production control, product evaluation and reliability, inventory control, and/or research and development teams as they apply to product or process quality.
Product / Supplier Quality Engineering Consultant
OSI Electronics, Electronics Manufacturing Services (EMS) · Contract
Mar 2016 - Jul 2016
Hawthorne, CA
●Supported Product / Supplier Engineering functions on New Product Introductions (NPI) and Build to Print PCBAs for Commercial, Aerospace, and Bio-Medical Industries (Electronics Manufacturing Services). Conforming to ISO - 9001, AS9100D, and ISO -13485 specifications.
●Conducted PPAP activities for Medtronics & Raytheon. Used AEGIS (Manufacturing Shop Floor Software), and NAVISION (ERP Software). CATSWEB Software utilization for CAPA and Customer Complaint resolutions.
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●Supported Root Cause Analysis & Corrective Actions (RCCA) using Quality Tools for all Customer Returns and Production Failures.
●Created and modified Product Process Flow, Control Plans, and PFMEAs. Created and reviewed First Article Inspection Reports (FAIR). Created PPAPs for Medtronics and Raytheon products.
●Certified IPC-A-610E Specialist.
Manufacturing / Quality Engineering Consultant
Edwards Lifesciences, Irvine, CA · Contract
Oct 2015 - Feb 2016 ·
Irvine, CA
●Supported Manufacturing / Quality Engineering Functions related to Cardiac Valves & Stents.
●Worked in Class 100,000 Clean Room Environment.
●Supported CAPA / NCR / PRD / Root Cause Analysis activities.
●Reviewed and Approved the FAIRs, and TFIQs for the Heart Valve Manufacturing Operations
Supplier / Product Quality Engineering Consultant
Advanced Sterilization Products (ASP), (A Johnson & Johnson Company) · Contract
Jul 2015 - Aug 2015 ·
Irvine, CA
●Supported Supplier / Product Quality Engineering Functions compliant ISO13485 Specifications on Sterilization products (Endoscopic & Surgical).
●Supported the External Suppliers on certification of the components and the raw materials used in the manufacturing of Sterilization products for the Hospitals and Medical Centres. Non-Conformances (NCR), SCAR resolutions, and CAPA (Corrective and Preventative Actions) implementations conform to ISO 13485 Specifications. Conducting Supplier Audits
FAA Quality Engineering Consultant, Product Support Group
Parker Aerospace (A Parker-Hannifan Company)
Feb 2014 - Feb 2015
Irvine, CA
●Supported Federal Aviation Administration (FAA Repair Service Depot) activities for World Wide Airlines in a Product Support Quality Engineering Role for Fluid Management Units (FMU), Pneumatic Valves, and Actuators.
●8D Problem Solving, Root Cause Analysis, and Corrective Action Implementations.
●Worked with multiple Suppliers as a Team to resolve incoming product issues (Quality, Delivery, and PPM reductions using Lean and Six Sigma Tools).
●MRB and Scrap Material Reductions. Conducted the training classes for Certified Operator Training (COP) for Assemblers, Inspectors and Technicians per FAA Repair Service Depot regulations.
●Reviewed NDT Reports on chemical etching, deep penetration, radiological testing, and ultrasonic testing
●Worked with DCAS personnel
●Worked on castings and mechanical aerospace components
Supplier Quality Assurance Engineering Consultant
Bio-Sense Webster Inc. (A Johnson & Johnson Company) · Contract
Oct 2013 - Jan 2014 · 4 mos.
Irwindale, CA
●Supported the External Suppliers on certification of the components & the raw materials used in the manufacturing of Heart Catheters. Non-Conformances (NCR), SCAR resolutions & CAPA (Corrective and Preventative Actions) implementations conform to ISO 13485 Specifications.
Supplier Quality Assurance Engineering Consultant, Raytheon Certified Six Sigma Specialist
Raytheon Space and Airborne Systems · Contract
Aug 2013 - Sep 2013
El Segundo, CA
●Supported the external supplier teams for (3) Raytheon facilities in CA, AZ, and TX on certifying the Rigid & Flex PCBs, PCB assemblies, Cable assemblies, and Electronic Components. Reviewed FAI reports and approved RCCA, and MRB activities.
●Supplier Product / Process Audits. Supplier Surveillance and Development.
Senior Product Quality Engineering Consultant
Honeywell Aerospace Defense & Space Satellite Systems ·
Oct 2012 - Dec 2012 ·
Glendale, AZ
●Supported all Product Quality related functions on Space and Defense Satellite System related products. Performed MRB activity and conducted (3) Kaizen Events.
●Attended training classes on J-001ES and NASA 8739 STD certifications.
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Senior Supplier Quality Engineer, Six Sigma Green Belt, Member of American Society for Quality (ASQ)
Kimball Electronics Group ( a subsidiary of Kimball International ) · Full-time
Aug 2011 - Aug 2012
Jasper, Indiana
●Supported the Supplier Quality Engineering group in the selection of PCBs / Electronics / Mechanical Component suppliers, conducting product/process audits including developing new suppliers and managing the existing ones.
●Conducted and Reviewed Failure Analysis reports implementing Corrective Actions on both Production / Field returns (RMAs) from Customers on the PCBAs manufactured by Kimball Electronics Group ( Both for Domestic and International locations in Thailand, China, Poland, and Mexico).
●AS9100D, ISO 9001, 13485, TS 16949, and TL 9000 QMS Compliant products.
●Validated PPAP, PFMEA & DFMEA with Suppliers.
●Reduced MRB Inventory & imposed preventative actions with the Suppliers.
●Validated the monthly Scorecards (PPM, Quality & Delivery Matrices) with Suppliers.
●Worked with Cross-Functional Teams ( Design, Manufacturing, Test, Field Service, and Program Engineering) to improve the Final yields to reach Zero Defects progressing towards a Goal of achieving 100% Customer Satisfaction.
●Six Sigma Green Belt.
●Member of MRB.
●Member of American Society of Quality (ASQ). Member Number: 64108945
Senior Manufacturing Test Engineer
iDirect Technologies ·
Aug 2010 - Jul 2011 · Herndon, VA
●Supported the Electronics Contract Manufacturers (Domestic and International) on iDirect's Sattelite Communications Networking Product's Testabilities.
●Participated in DFM, and DFT analysis of new products.
●Conducted Product Failure Investigations (both production and field returns) and implemented Corrective Actions.
●Improvised Product Quality / Reliability and worked towards to 100% Customer Satisfaction.
Adjunct Professor
California State Polytechnic University · Part-time
Mar 2000 - Aug 2010 ·
Pomona, CA
●Taught various courses for B.S.E.E.T Degree Programs from Basic AC / DC Electronics, Digital, Analog thru Motorola and Intel Microprocessors.
●IBM PC System Maintenance and Novell Networking Course.
●Edited Mc-Graw Hill published Electronics Textbook.
●Lab classes on Assembling, Testing, and Troubleshooting IBM-compatible computers along with other Hands - On Special Electronics Projects.
●Taught various Software application programs (MS Office)
●Developed the Course Curriculum, Technical documents and Lesson plans
Senior Hardware Test Engineering Consultant
Curtisswright Controls Embedded Computing ·
Apr 2009 - Jul 2009 ·
Chatsworth, CA
●Reported to V.P. of Operations
●Generated / Modified Acceptance Test Procedures/Assembly Instructions for VME, PCI, and PMC Memory Modules. BOM checks, Gerber Files, and Schematics Verifications.
●Executed complete Product Manufacturing / Test Process transfer efforts along with complete Data Packages from CA, U.S.A. to a Contract Manufacturer in CANADA.
Test Engineering Manager
Cal Quality Electronics (Electronics Contract Manufacturer) ·
Nov 2008 - Mar 2009
Santa Ana, CA
●Reported to Executive V.P. of Program Management
●Managed a Test group of (12) including Test Engineers, Test Technicians, and Rework Personnel.
●Responsible for various Medical; Military, Defense, NASA, and Commercial Programs conducting In-Circuit test (ICT), Functional test (FT), and JTAG testing of the Electronic Modules (PCBA)s, Sub-Systems, and Final System Level conforming to Customer Acceptance Test Procedures (ATP).
●Responsible for Customer returned RMA and F.A. reports.
Performed Employee Performance Reviews and handled Day to Day Test activities working closely with Customers and Program / Project Management requests.
Purchased Capital Equipment and Contract services for ICT, FT Program creation, and execution.
Assisted the Technicians and Engineers on several Hands-On Troubleshooting Test Failures.
Responsible for relocating the Test Area (Equipment Layout and Installation ) from an existing (1,000 Sq') to a (5,000 Sq') new remodeled Test Facility within the Company.
Generated additional revenue by repairing the Bone Piles of Defective Modules.
Sr. Sustaining Engineer
L-3 Communications / Power Paragon Inc. · Full-time
Jan 2008 - Sep 2008
Anaheim, CA
●Supported Multiple Programs generating a record number of Failure Analysis Reports (525+) on both the Production and Field Returned systems and sub-systems.
●Member of Failure Review Board (FRB) analyzing the test yield trends and product failures on Power Systems / Static Transfer Switches for U.S. Surface, Nuclear Navy and Commercial customers.
●Supported the New Product Teams on DFM and DFT analysis working with the Program Management.
●Trained the Test Technicians and Test Engineers on Fault Isolation and Troubleshooting Techniques in the Production / FAA Repair Depot areas.
●Improvised the failure data entry process into (Tip-QA) for accurate reporting
● Consolidated the feedback data from field returns and alerted the production floor on a real time basis in detecting the root cause of the failures and implemented immediate corrective actions (FRACAS), thereby preventing the reoccurrences of the field failures. Cleared the failure report backlog of (2 years) on the customer returned failures and brought it back to current.
●Worked with (FMECA) interfacing with the Product Design Engineers and conducted Reliability predictions using MIL-STD 217 Handbook.
●Reduced the Component failures / Workmanship defects by (35%) in (2) quarters by working closely with FRB Team members from (Design, Manufacturing, Test, and Quality Engineering.
Senior Quality Assurance Engineering Consultant
DRS Technologies · ContractDRS Technologies · Contract
Aug 2007 - Sep 2007 ·
Cypress, CA
●Supported and Supervised (6) Quality Personnel working on Electro-Optic Sensor (EOS) products.
●Conducted PCB Supplier visits and audited the internal processes. Participated in MRB activities.
●Worked in Class (10,000) Clean Room facility and generated NCMRs, Failure Analysis reports (FARS) for NASA's Customers.
Senior Quality Assurance Engineering Consultant
Goodrich Corporation · Contract
Jun 2007 - Jul 2007 ·
Diamond Bar, CA
●Developed the Training Materials for FAA Repair Station personnel and trained them on the Repair Depot process guidelines.
● Participated in (2) Kaizen events and created common parts usage in assemblies.
●Created and modified the Work Instructions and Quality Process Procedures in Quality Manual for the Quality Department personnel to be used in the repair of Helicopter Hoists and Winches.
Senior Quality Assurance Engineer
Teledyne Microelectronic Technologies · Full-Time
Nov 2006 - Feb 2007
Marina Del Ray, CA
Supported all the Quality functions leading a group of (15) Q.A. personnel on Solid State Relays & Power Devices Product Lines in compliance with MIL- PRF -38534, MIL- PRF -28750, MIL-STD 883 STD including interfacing with DSCC. (Supervised Receiving Inspection, Final Inspection, Product qualification, Customer product failure investigations, Root cause analysis and Corrective actions).
●Conducted Product / Process Audits, FAI, and ROHS. Saved ($50K) by eliminating the scrap on the Relay products by controlling the false failures. Used the Optical Microscopes, XRF equipment, Micro-Probing Station, and X-Ray Machines in the failure analysis of HYBRID MICRO CIRCUITS, DC to DC Power Hybrid Modules, Solid State Relays, and Flex Circuit card assemblies.
Principal Multi-Disciplined Engineer
Raytheon Space and Airborne Systems · Full-time
Oct 2003 - Aug 2006
El Segundo, CA
●Reported to the Section Manager
●Supported the Test Engineering Group developing the Automatic Test programs on Cirrus CH+ Easy-Wire Series Cable Test Equipment for all the Cable Assemblies (STE and FLIGHT) testing used for Multiple Programs/Projects (AVALON, PLUTO, S2E, ROA, TMOS, STSS /SBRIS) in the Space Products Manufacturing Lab (SPML).
●Created a new robust Cable Test Process to be implemented across all programs and saved ($200K) in manufacturing and test costs.
●Supported the Special Test Equipment (STE) projects as a STE Project / Test Lead managing (6) Test Engineers on Multiple DOD and Space Programs (APL-5 & MP-RTIP) interfacing with IPT and the Program Management Team.
●Successfully completed an interdepartmental assignment in System Engineering Center (AI&T Team) conducting the Electro-Optical Sensor (EOS) Payload Integration effort in an Integrated Test Facility (ITF) (10, 000) Clean Room for the STSS /SBRIS (Block 06) program for Northrop Grumman Corporation.
● Attended training courses on Project Management, Leading for Value and EVMS.
●Chaired the STE Internal Preliminary Design Reviews (IPDR) and Critical Design Reviews (ICDR) on J-F-15 program. Participated in Risk Management and Mitigation activities for several Programs.
●Lead Engineering Liaison Support on the Test Development and Software Validation on Processor Test Station, Manufacturing and Testing of the Electronics Modules working with Celestica (EMS) Contract Manufacturer for U.S. Navy's ATFLIR Program.
●Saved ($10M) as a Member of the "Tiger Team",during the entire Life Cycle of the Program by solving the Environmental Test Failures on the Processor Module Chassis supporting the ATFLIR.
●Worked on RadStone I/O, Control, VME and SBC Modules.
Sr. Manufacturing Electronics Engineer
La Gard Inc · Full-time
Sep 2002 - Jul 2003
Torrance, CA
●Reported to V.P. of West Coast Mfg. Operations
●Responsible for improving the printed circuit board assembly (PCBA) Manufacturing and Test processes (SMT & PTH) on Multiple New and Existing Products (200 types) in compliance with (IPC - 600 & 610 STD) used in the manufacturing of Smart Security Electronic Modules and Mechanical Locks for the Hospitality and Banking Industries.
●Performed the failure analysis on the customer returns (RMAs) and implemented the corrective actions after conducting the root cause analysis of the failure modes.
●Worked with (EEE) Component Obsolescence, researched for substitute components from different vendors supporting the design and material procurement departments.
Saved the company ($250K) in manufacturing and test costs by refining the test process, replacing test fixtures, and reducing the product test time cycles by (30%) on the Teradyne 1850 In-Circuit Tester(ICT).
Hired and Trained Assembly, Rework personnel, and Test Technicians (15) conforming to (IPC-A-610 and J-001) Inspection and Soldering Standards.
Worked with New Product Introductions (NPI) from the Designed phase to Final production and managed product manufacturing/test transitions from Michigan to California.
Interfaced with Multiple Cross-Functional Teams (Design, Manufacturing, Test, Component, and Quality Engineering) to maximize product test yields and improve overall product quality.
Quality Engineer / Failure Analysis Lab Supervisor
Simple Technology (STEC)
Apr 2001 - Aug 2002 ·
Santa Ana, CA
●Reported to Director of Quality
●Responsible for improving new product production test yields and analyzing the failures on the customer's returned Multiple Semiconductor SRAM, SDRAM, DDR, Flash Memory PCB Modules (1000 types) and the FLASH DRIVES. ISO 9001 Certified Company. Conducted the On Going reliability tests (ORT) on the products.
●Generated the internal corrective actions (ICAR) for both Manufacturing / Test processes to continuously improve the production and test flows and product test yields.
●Saved the Company ($300K) by implementing a new process flow to minimize the customer returns.
●Hired and Trained Test Engineers/Technicians in a team approach method to achieve goals and improve productivity. Conducted product qualification tests per JEDEC standards and submitted reliability reports to the Management.
●Validated the test software for test coverage and eliminated the false failures.
●Interfaced with the Memory Component Vendors on the failures and reviewed the failure analysis reports.
●Generated failure analysis reports for both production and (OEM) customer's (UNISYS, CISCO, EMC) product returns.
●Used Test Program Debug tools (e.g.: Hex Works, Win Flash v 3.71) to analyze the failures on Flash memory products.
●Conducted HITACHI's Engineering Verification Test (EVT) qualifications on the Flash Memory products, summarized the failure analysis, recommended the corrective actions and submitted the final F.A. reports.
●Performed the internal and external product / process audits and issued (NCMRS, ICARS and SCARS).
●Created a new Failure Analysis Lab (FAL) and managed a team of (10) Test Engineers / Techs / Inspection and Rework personnel.
●Reviewed and purchased new Capital Test Equipment (High Magnifier Microscope, Digital Oscilloscope, Huntron Fault Analyzer and Logic Analyzer) needed for the FAL to troubleshoot the defective Memory Modules and Components.
Sr. Manufacturing Project Engineer
Rockwell Collins Inc
Jan 1999 - Mar 2001 ·
Pomona, CA
●Responsible for Improving the Manufacturing / Test processes in the Manufacturing facility (Mexicali) maximizing the test yields and minimizing overall product / project costs.
●Supported (DFM) and (DFT) functions in the initial phase of the In - Flight Entertainment (IFE) Audio and Video R.F. (PCBAs with SMT & PTH) (100 types) including the Cable harness assemblies for the Major Airlines Worldwide.
●Participated in Company's Lean Electronics Initiatives to minimize waste and maximize productivity resulting in significant product cost savings. AS9100 compliance related products and systems.
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●Worked as a Technical Liaison for the Design, Systems, Component, Quality and Customer Support Organizations to continuously improve the product quality and provide timely feedback to correct the deficiencies as they arise both during the initial stages and the entire product life cycle. Interfaced with SCI Systems, Maine (Contract Manufacturer).
●Resolved Technical and Yield issues with various vendors across the U.S.A./ Mexico (Supplier Quality Management).
●Generated the Test Procedures (TP), Test Requirement Documents (TRD) and (SCD) documents.
●Worked with (EEE) Component Obsolescence: researched for alternate components and vendors supporting the Design Engineering and Material Procurement Departments.
●Increased the Test Yields and Reliability of the Audio Video unit (AVU) product line from (79% to 99%) of final acceptance.
●Saved the Corporation ($1M$) in Production and RMA repair costs.
●Worked with FAA Repair Facility and managed the Repair Depot activities of (10) Test Technicians to minimize field returns.
Sr. Test Engineer / Member of Continuous Improvement GroupSr. Test Engineer / Member of Continuous Improvement Group
●Attended the Boeing D1-9000 Quality Process training classes (80 hrs) and earned the BOEING Company Certification.
Teradyne · Full-time
Feb 1996 - Oct 1998
Agoura Hills, CA
Responsible for the reduction of PCBA / ASIC / SMT Electronic Component failures both in Module and System Test departments by understanding the failure modes/ trends. Interfaced with Solectron (Contract Manufacturer).
●Achieved an Overall (90%) reduction (PPM) in the failures of ASICs/Components (PTH & SMT) by analyzing the different stages of the processes in PCB Assembly, Manufacturing/Test departments for deficiencies and implementing the corrective actions using Total Quality Management (TQM) and (SPC) techniques.
● Trained and Supervised Test Engineers and Technicians (30) with established Fault Isolation/Troubleshooting techniques and focused on the Team Effort to achieve the Goals. Worked closely with Field Support groups.
●Maintained Consistent Quality Improvement for (8) Consecutive Quarters and saved approximately ($950K) in parts and labor costs for the Corporation.
●Participated in (ISO 9002) Process Audit related activities.
● Conducted Environmental Stress Screening (ESS) tests on the potential new products and submitted the reports to the Management for feasibility studies.
●Programmed the Teradyne's Automatic Optical Inspection System (AOI) 5539C online, after the solder reflow process for identifying Solder and SMT component placement defects prior to PCB Test to minimize the failures, which resulted in overall reduced costs on parts and labor.
●Interfaced with Design, System, Design for Manufacturability (DFM), Design for Testability (DFT) and Component Engineering teams in a Concurrent Engineering Activity role to foresee any potential Hardware and Software issues on the existing (500 types) and New Product Introductions (NPI). Worked with PWB vendors and resolved Fabrication Issues.
● Conducted the Design of Experiments (DOE) as needed in the Manufacturing and Test Areas.
●Participated both as a Team Leader and Team Member in Various Quality Improvement Teams (QITs).
EDUCATION:
M.S.E.E. in Computer Hardware Engineering
California State Polytechnic University-Pomona
Bachelor of Science in Electrical Engineering (B.S.E.E.)
Osmania University, Hyderabad, India
Six Sigma Green Belt Trained
Certified Six Sigma Specialist, Raytheon
Certified IPC-A-610E Specialist
Adjunct Faculty (BSET Program) - Cal Poly University, Devry University, ITT, Pomona, CA
Member of American Society for Quality
Member of IEEE
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