Manufacturing Enginner

KALYAN PUSALA

210-***-**** **************@*****.***

LinkedIn:linkedin.com/in/kalyan-pusala-691768300

PROFESSIONAL SUMMARY

Results-driven Manufacturing Engineer with 3+ years of specialized experience optimizing production systems and enhancing product quality in automotive and diesel engine manufacturing. Combines deep expertise in Lean Six Sigma methodologies with practical knowledge of quality management systems to deliver measurable improvements in operational efficiency and cost reduction. Skilled in leading cross-functional teams through complex process validation, new product introduction, and continuous improvement initiatives. Proven ability to implement robust quality controls, streamline manufacturing operations, and drive sustainable productivity gains while maintaining compliance with IATF 16949 and ISO 9001 standards.

Technical Skills

Manufacturing & Process Excellence: Lean Manufacturing, Six Sigma (Green Belt), Continuous Improvement

(Kaizen, 5S), Value Stream Mapping, TPM, SMED, Line Balancing, Capacity Planning, Cycle Time Analysis, Ergonomic Evaluations, Production Scheduling, Factory Layout, Process Validation, Standardized Work, Yield Improvement, OEE Optimization

Quality Systems: APQP, PPAP, FMEA, Control Plans, SPC, MSA, 8D, Root Cause Analysis, ISO 9001, IATF 16949, Supplier Quality Management, Audit Compliance, Gage R&R, Capability Studies, Quality Audits, Non- Conformance Management, Corrective Action Systems, Quality Planning

Engineering & Metrology: GD&T, SolidWorks, AutoCAD, CMM Operation, Gage Design, Calibration Procedures, First Article Inspection, Tooling Design, Fixture Design, Process Documentation, Technical Specifications, Dimensional Analysis, Tolerance Stack-up Analysis, Prototype Development

Project Management: Cross-Functional Leadership, Technical Documentation, Cost-Benefit Analysis, Risk Mitigation, Workflow Optimization, Capital Expenditure Planning, Vendor Management, Stakeholder Communication, Project Scheduling, Resource Allocation, KPI Monitoring PROFESSIONAL EXPERIENCE

Cummins Inc Manufacturing Engineer New York, NY Jan 2024 — Present

Reduced process variation by 15% for critical engine assembly parameters through Statistical Process Control implementation and line balancing optimization.

Launched two new assembly lines on schedule by authoring all PFMEAs and Control Plans, achieving 100% on-time APQP milestones.

Eliminated $80,000 in annual warranty claims by leading a cross-functional team to diagnose and resolve a chronic engine seal leak.

Eradicated a recurring turbocharger misalignment defect by designing and implementing a Poka-Yoke fixture.

Improved First-Pass Yield by 8% on a key assembly line by developing and delivering standardized inspection training for 12 production operators.

Accelerated engineering change implementation from 80% to 95% on-time by establishing a project management framework for tracking ECNs.

Cut new hire training time by 25% for 5 complex assembly stations by authoring and standardizing work instructions.

Enhanced production line efficiency by 12% through time-motion studies and implementation of standardized work procedures.

Reduced machine setup time by 30% by applying SMED (Single-Minute Exchange of Die) principles to critical machining centres.

Improved supplier quality performance by conducting on-site audits and implementing rigorous incoming inspection protocols.

Ashok Leyland Quality Engineer India Aug 2021 - Jun 2023

Reduced final assembly defects by 12% by applying Pareto analysis to prioritize and address the top 3 failure modes.

Accelerated incoming inspection cycle time by 20% by leading a Kaizen event that redesigned layout and optimized material flow.

Strengthened 10+ critical machining processes by executing capability studies, ensuring a minimum Cpk of 1.33.

Reclaimed 25% of floor space in the welding department through a 5S initiative, reducing tool search time by 5 minutes per shift.

Boosted uptime for critical CNC machines by 5% by initiating a Total Productive Maintenance partnership with maintenance teams.

Reduced incoming defect rates from key vendors by 18% by developing a supplier quality scorecard system.

Prevented a potential $50,000 line stoppage by conducting a pre-emptive FMEA that led to a critical design change.

Improved measurement system reliability by conducting Gage R&R studies that reduced measurement variation by 40%.

Enhanced customer satisfaction ratings by 15% through rigorous implementation of corrective actions for field failures.

Reduced calibration costs by 20% by optimizing calibration schedules and implementing a streamlined tracking system.

EDUCATION

Master of Science, Industrial Engineering Texas A&M University-Kingsville, Kingsville, TX

Bachelor of Engineering, Mechanical Engineering Guru Nanak Institutions Technical Campus, India Certifications:

• Certified Lean Six Sigma Green Belt

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