Quality Assurance R D

Roopkatha Pallye, Ph.D.

*******@*****.***•734-***-****

LinkedIn • Redmond, Washington 98052

Lead Materials Engineer - Softgoods

Innovative and results-driven Materials Engineer with a Ph.D. in Textile Technology and 8+ years of experience in advanced materials testing, process optimization, and softgoods R&D.

Proven success in developing and validating textile and polymer solutions for automotive and wearable systems. Expert in DOE, root cause analysis, and AI-driven data interpretation. Adept at leading cross-functional teams to solve complex technical challenges, reduce costs, and enhance product performance. Recognized for award-winning research and product development showcased at international platforms. Committed to sustainable materials innovation and quality assurance across global manufacturing environments.

Areas of Expertise

Design of Experiments (DOE)

Root Cause Analysis

Cross-functional Collaboration

AI-driven Data Analysis

Quality Assurance

Process Improvement

Material Testing & Characterization

Statistical Data Analysis

Optimization of Testing Procedures

Career Experience

Meta/Facebook Platforms LLC, Redmond, WA 10/2023 – 05/2025

R&D Test Engineer III, Reality Labs – Contract

Lead lab operations and spearhead instrument development for testing and characterizing soft polymers and engineered textiles in wearable systems. Generate Python and MATLAB code using ML and NLP to streamline data analysis and bridge domain-specific knowledge gaps. Conduct root cause analysis to address and prevent process issues. Collaborate with cross-functional teams to implement process improvements and meet project objectives.

Introduced novel validation protocols and instrumentations.

Optimized testing protocols through DOE, reducing testing time by 78.26%.

Evaluated instrument-to-instrument variance and system-level errors via DOE, increasing testing flexibility and efficiency.

Stellantis, Auburn Hills, MI 10/2022 – 08/2023

Materials Engineer - Contract

Selected and tested various materials including textiles, fabric, carpets, headliners, foams, and threads while approving new constructions and assessing color durability for soft trims. Conducted mechanical, electrical, thermal, tensile, moisture management, and weather exposure tests with both internal and supplier teams. Authored and validated material standards and lab test procedures, addressing root causes for ongoing production issues and supporting polymer product development. Researched and developed sustainable material alternatives for carbon footprint reduction. Collaborated with product design and color, materials, and finishing teams to ensure alignment on haptics and color specifications.

Executed global harmonization of ex-PSA and ex-FCA Material Standards for Soft Trims across EU, LATAM, and IAP regions as Material Technical Expertise for North America.

Adient U.S LLC. (Stellantis B.U.), Plymouth, MI 01/2020 – 08/2022

Quality Analyst III

Conducted thorough analyses of products, systems, and software to ensure adherence to organizational quality standards, minimizing defects. Strategized, designed, and implemented comprehensive test and process plans for prominent projects, assessing reliability, performance, and quality. Supported soft trim engineering with advanced material expertise. Collected and analyzed statistical data, identifying patterns and trends to inform senior management and other relevant stakeholders. Oversaw the enhancement of product quality through continual assessment and adjustment of existing processes.

Reduced year-over-year warranty costs by 20% while increasing supplier chargebacks by $50K through effective resolution of quality issues.

Adient U.S LLC. / Johnson Controls Inc., Plymouth, MI 10/2016 – 12/2019

Engineering Intern

Executed research and analysis while collaborating with cross-functional teams to facilitate seamless daily operations. Coordinated the implementation of innovative engineering solutions to enhance efficiency and optimize processes. Conducted a thorough analysis to support the development of advanced tools for risk assessment and parameter forecasting. Assisted in the authorization of process parameters in manufacturing facilities to improve monitoring and cost management.

Formulated and designed a Wrinkle Risk Assessment Tool by identifying and documenting best engineering practices in trim, foam, and seat system design.

Developed an analytical tool to forecast sewing machine parameters from thread consumption, improving root cause analysis of JIT-built parts and automotive trims.

Authorized and implemented process parameters at Ciudad Juarez manufacturing plants, leading to efficient monitoring, cost optimization, and continuous improvement.

Enhanced production rate and quality, and reduced costs by optimizing industrial sewing machine parameters, saving 15.6% of time and 3 to 5% of costs using DOEs.

Additional Experience

Graduate Research Assistant Doctoral Fellow, Eastern Michigan University, College of Technology, Ypsilanti, MI

Industrial Trainee, Aditya Birla Grasim, Textiles Division, Rishra, Kolkata, WB, India

Education

Ph.D. – Engineering Technology, Concentration in Textile Technology, GPA 3.71

Eastern Michigan University, College of Technology, Ypsilanti, MI, 2019

Master of Science – Apparel, Textiles, and Merchandising, GPA 3.78

Eastern Michigan University, College of Technology, Ypsilanti, MI, 2017

Bachelor of Technology – Textile Technology, GPA 3.98

University of Calcutta (Int. of Jute & Fiber Tech.), Kolkata, India, 2015

Accomplishments

Awarded Best Technical Poster by the Detroit Society for Coatings Technology (2019) for excellence in research presentation and technical innovation.

Selected Exhibitor at the North American International Auto Show (2018), showcasing developed superhydrophobic PET automotive soft trim for Automobili D.

Recognized as Best All-Round Intern at Adient U.S. LLC (formerly Johnson Controls Inc.) in 2016 for outstanding performance, initiative, and cross-functional contributions.

Technical Skills

Minitab SPSS Python MATLAB MS Office Suite AutoCAD Windows Mac OS Gerber

Affiliations

Secretary of Indian Student Association, Eastern Michigan University, College of Technology, Ypsilanti, MI (2015 – 2016)

Elected General Secretary of Student Union, University of Calcutta, Kolkata, India (2015)

Elected Vice President of Student Union, University of Calcutta, Kolkata, India (2013 – 2014)

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