Manufacturing Engineer Process
Resume:
VENKATESWARA RAO LOKAM
Sr. MANUFACTURING PROCESS ENGINEER
******.*******@*****.***
Fort Payne 35967
Manufacturing Engineer with 8+ years of experience designing and improving manufacturing processes. Autonomous and self-driving at implementing complex manufacturing strategies from the design phase to the point of being fully operational. Proven track record of knowing how to identify deficiencies and implement improvements to reduce costs and increase productivity.
AREA OF EXPERIENCE:
•Manufacturing & Production (CNC & SPM, Sheet metal Stamping, NPI, welding.)
•Quality (SPC, TQM, FMEA,7QC tools, In-process, and final inspection)
•Lean Manufacturing Techniques, TPM.
•Technical Analysis
•Value Stream mapping (VSM)
•Supply chain management
•Geometrical Dimensions and Tolerances (GD&T)
•Quality management System(QMS)
BOM (bill of material)
Supplier coordination
•Progressive dies, moulds & Casting
•CAPEX projects Handling
•Jigs & fixtures
•Process development
•APQP, PPAP (production part approval process)
•Root cause analysis & solving problems (RCA)
•Sourcing,negotiation
•Planning schedules
•R&D, Assembly Techniques
CURRENT EMPLOYER: - “Harley Davidson”,
Sr. Manufacturing Process Engineer, York-PA from March 2022 – Oct 2024
Play a key role in developing, implementing, and documenting manufacturing processes for products.
Drove the delivery of 12 new subassembly product introductions, which are contains 100s of individual parts, handling all phases of manufacturing process (from the initial concept to the production dispatch)
Maintain PFMEA records and KPI strategies.
Supply chain activities (handling the raw material, coordinates with suppliers, logistics and third-party manufacturers)
Done many Simulations in Auto cad, and various 3D design software’s.
Sourcing Tools from around the globe.
Production activities, material handling, machine & manpower utilization.
• Study time, motion, methods, and speed involved in maintenance, production, and other operations to establish standard production rate and improve efficiency.
Proficient in conducting PHA (process hazard analysis).
• Aid in planning work assignments in accordance with worker performance, machine capacity, production schedules, and anticipated delays.
PPAP & APQP process done for many Existing and new components and gained customers satisfaction.
Created assembly documents for 230+ individual products in less than 3 months.
Increased arrival quality scores from 82% to 99.97%, ensuring the defect-free shipment of products over a 2-year period by applying statistical process controls
Developed detailed mechanical assembly drawings for multiple products, increasing overall productivity by 27%
Value stream mapping and lean methodologies applied on production line.
Designed and modified various types of Jigs & Fixtures in shop floor.
Harley Davidson – Chennai, INDIA
Sr. Manufacturing engineer, January 2015- October 2021.
Value stream mapping,Lean concepts applied in Die and mold making unit.
Used to handle all the operations of manufacturing and export of Dies, molds, Jigs & fixtures, stamping components and plastic components to middle east countries.
Achieved many critical parts by Progressive dies and cam molds.
Designed and manufactured all types of Jigs and fixtures to robotic welding’s.
Communicated well with Clients and vendors.
Develop evaluate manufacturing processes.
Drafts blueprints and detailed drawings from auto cad and solid works
Specialized Factory for Steel Products, Jeddah- Saudi Arabia
Jr. Manufacturing process engineer Nov -2012 to 2014 oct.
Integrated hardware and software, designed power distribution boards, and delivered product line support for a $500M instrumentation and equipment manufacturer
Improved workflow operations and reduced manufacturing time by 20% using Six Sigma and Lean Manufacturing methodologies
Improved the order fulfillment process, thus eliminating unwanted activities and reducing the time from a sample request to order placement by 30%
Implemented Lean Work Flow Operations for sheet metal components for various industries, reducing cycle time by 20%
Continually reviewed production flow and implemented workflow improvements to reduce complexity, redundancy, and cycle time, increasing profit by 9%
Managed over 125,000 production labor hours with a budget value in excess of $47M
CURRENT ROLES & RESPONSIBILITIES:
•Continuous improvements - KAIZEN.
•Reduce rejections and reworks for daily/ monthly.
•Reduce internal /external Customer complaints and modifying accordingly.
•Process updates in FMEA and Control plan,
•KAIZENS, QC Projects, 5S, Multi skilling of Workers etc.…
•Plan, organize and direct the manufacturing operations and process.
•DFMA & PFMEA
•Reducing rejections by daily monitoring CAPA.
•Support to Delivering products On Time to internal and external customers.
•Handling BOMs (Bill of Materials).
•On job Training & evaluating of Workmanship to improve Skill matrix
•Man, machine, equipment & material Cost awareness in my team.
•Coordinating with cross functional teams.
•ERP based all entries. Assembly process.
LEAN MANUFACTURING
•Monitor Production System Tracking Board and make CAPA accordingly.
•Man, machine utilization and capacity, Productivity, OEE, value stream mapping and Takt time calculations.
•Calculating, Monitoring & reduce, PPM.
Line balancing threw Reduce Changeover time, Bottle necks, cycle time.
•Non-Value added etc. in the process to improve productivity.
•Driving the Continuous kaizen Projects on 5’S, Waste elimination, TPM, Visual management etc…
QUALITY
•Attend customer complaints and make CAPA accordingly.
•Rejection analysis daily with CAPA.
•Root cause analysis threw Why-why analysis, 7 QC tools.
•Cross functional participation for development of SOP, Control plan & PFMEA.
•PFMEA upgrading, revising as per Quality issues and customer complaints.
•Monitoring, Measuring & Control of Rejection, Rework & Scrap cost.
METHODS:
•New projects Equipment drawing to supplier, supplier support and follow-up, receive material, Check, trail and modify if required.
•Monitoring, Measuring & Reduce Non- value Added in process.
•Standardization of Standard operating procedures.
Productivity/Cost Projects:
•Consumable/tooling cost reduction.
•Reduction of tool changer over time by increasing of tool life.
•operation eliminations / add through KAIZEN.
•Identify the bottleneck and adjust the process.
Quality Projects:
•Overall rejections were reduced by 5%.
•Cage damage rejection was reduced by 3% in punching operation by placing Poka-yoke.
•2 Poka-yokes initiated and completed for rejections and customer quality.
Education:
QUALIFICATION
BOARD / INSTITUTE
YEAR of PASSING
Percentage
Master of Science in Technology Management
Lindsey Wilson College
2023
91.0
Bachelors in Mechanical Engineering
Parul University
2012
77.0
Diploma in Tool & Die making.
N.T.T. F
2009
72.5
Industrial skills:
•Total productivity maintenance (TPM).
•Total Quality management (TQM).
•Ergonomics.
•FMEA & PFMEA
•5S.
•Lean Manufacturing.
•Problem solving QC story methodology and DOE techniques.
•SMED
SOFT SKILLS
•Auto cad
•Creo
•Solid works
•MS Office (Ms Excel, Ms word, Ms powerpoint)
•CATIA
•ERP
I hereby declare that the above furnished details are true to the best of my knowledge.
VENKATESWARA RAO LOKAM
Contact this candidate