Industrial Engineering for Lean Manufacturing Excellence

SENTHILKUMAR VIDHYA MANIKANDAN

240-***-**** ********@***.*** LinkedIn USA

EDUCATION Arizona State University, Tempe, Arizona, USA May 2026 Master of Science in Industrial Engineering, focusing on Industrial Manufacturing, Quality, Lean Six Sigma, Management Anna University, Chennai, India Oct 2024

Bachelor of Engineering in Computer Science Engineering, focusing on Data Structures, Artificial Intelligence, Data Analysis

SolidWorks & AutoCAD ISO 9001, IATF 16949 Project Management Professional

GD&T & ASME Y14.5 Six Sigma Green Belt & Lean Manufacturing EXPERIENCE Action Spring, Chennai, India May 2025-Aug 2025 Manufacturing Process Engineering Intern – Lean Manufacturing, Six Sigma, Project Management, Quality, Production,

Optimized austempering soak and quench parameters using Design of Experiments (DOE) and Statistical Process Control

(SPC), improving hardness uniformity, reducing rejections by 15%, and strengthening process capability (Cp/Cpk).

Implemented sheet metal forming and austempering heat treatment processes for automotive components supplied to Hyundai and ITW, ensuring metallurgical integrity, dimensional accuracy, and compliance with ISO/TS standards.

Standardized inspection checkpoints, process documentation, and work instructions across forming and heat treatment operations, strengthening Quality management systems, improving traceability, ensuring audit readiness, and driving compliance with OEM requirements, ISO standards, and customer-specific quality protocols.

Led optimization of power press operations by calibrating tooling, integrating poka-yoke mechanisms, and applying GD&T principles to reduce variability and deliver a 10% efficiency gain.

Collaborated with cross-functional teams to conduct Root Cause Analysis (RCA), implement Corrective and Preventive Actions (CAPA), and lead continuous improvement projects, reducing downtime, reinforcing long-term process capability, and sustaining higher levels of production reliability and operational efficiency.

Implemented DFM/DFA guidelines and conducted assembly analysis to identify design inefficiencies, eliminate non-value- added activities, and support Lean manufacturing practices, improving production throughput and cost-effectiveness. Sakthi Spring Forms Pvt. Ltd, Chennai, India Aug 2021-Aug 2022 Manufacturing NPI Engineer Intern – Operations, Process Improvements, Warehouse Management, Kaizen

Optimized oil-quench heat treatment cycles by recalibrating soak and quench parameters, improving hardness uniformity and delivering a 12% increase in process efficiency and long-term production stability.

Streamlined warehouse management processes with Kanban scheduling, reducing idle time, saving $8K annually, and ensuring on-time material availability to support uninterrupted OEM supply requirements.

Reduced process variability by 10% by standardizing furnace operating controls and implementing enhanced temperature monitoring systems, strengthening overall process reliability and product consistency.

Decreased scrap rates by 14% through Kaizen-driven continuous improvements, reinforcing Lean Manufacturing practices and improving supplier credibility, audit readiness, and OEM compliance with Valeo and Brakes India.

Ensured ISO compliance by aligning inspection protocols, SOPs, and documentation practices with evolving customer- specific quality standards, sustaining trust with Lucas TVS and IM Gears. Sakthi Spring Forms Pvt. Ltd, Chennai, India June 2023-June 2024 Manufacturing Quality Engineer Intern – Quality, Project Management, Design, Development, Continuous Improvement

Executed root cause analysis (RCA) and implemented Corrective and Preventive Actions (CAPA), eliminating recurring press defects and delivering a 15% reduction in quality issues across production lines.

Accelerated PPAP approvals by one week by aligning APQP deliverables including PFMEA, Control Plan, MSA, and GR&R with customer audit standards, improving compliance readiness and reducing approval delays.

Reduced rework and scrap by 12% by applying Statistical Process Control (SPC) techniques and sustaining process capability performance (Cp, Cpk 1.33) for forming and heat treatment operations.

Improved customer satisfaction by 10% through strengthened inspection protocols, revised quality gates, and closer collaboration with internal quality teams and external supplier networks.

Facilitated Kaizen events and led cross-functional workshops, embedding a culture of continuous improvement, reinforcing ISO compliance standards, and ensuring sustainable long-term audit readiness. Yakkay Technologies, Chennai,India Feb 2023-Mar 2023 Data Analyst Intern – Data Analytics, Visualization, Decision Support, Process Optimization

Processed and interpreted large-scale, complex datasets, extracting meaningful information, enhancing data efficiency, and supporting business operations with improved reporting accuracy and reliability.

Utilized Apache Spark, SQL, Excel, Java, and Python to perform advanced data analysis, streamline workflows, and manage large-scale datasets with a 30% improvement in accuracy, consistency, and speed.

Generated data-driven insights that enhanced decision-making processes and optimized operational strategies, contributing to a 20% boost in efficiency and improved resource utilization.

Designed and deployed visualizations and dashboards using Knime Analytics and Power BI, presenting data trends through charts, graphs, and interactive reports for stakeholders across multiple functions.

Collaborated with cross-functional teams to translate analytical findings into actionable recommendations, reinforcing business intelligence, strategic planning, and long-term organizational growth. SKILLS SolidWorks AutoCAD Project Management Jira Confluence Smartsheet JMP Pro ISO Standards Minitab Power BI Data Analysis Suppliers 8D A3 Pareto Analysis Line Balancing SQL WIP Six Sigma VSM PDCA DMAIC OEE Waste Elimination Work Measurement Supply Chain Kaizen Inventory Control Process Analysis Lean Manufacturing 5M Regression

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