Quality Assurance Engineer NPI and Manufacturing Excellence

Quality Engineer - Sienna Corporation, Suwanee, GA Nov 2022 – Present

• Supported end-to-end New Product Introduction (NPI) activities products which include – Eletro Mechanical, Electrical and electronic assembies,system integration

• Developed and own Process Flow Diagrams (PFD), PFMEA, and Control Plans for multiple Electromechanical and electrical assemblies (Energy storage system assemblies like inverters, control panels, power optimizers, tesla site controllers, PV Hub and multiple PCBA’s asssmeblies)

• Prepared First Article Reports (FARs) for Electrical and electronic assembbles, ensuring product conformance to drawings, specifications, and customer requirements.

• Created and maintained IQC inspection plans for over 200 + Mechanical parts, wire harness

• Handled cutomer complaints, internal non-confromaces, supplier quality issues

• Developed and implemented in-process and OQC inspection plans for electromechanical and electrical assemblies to ensure product quality

• Created Work instructions and MES(Factory logix)processes for new and existing products

• Created DFA report for Power electronic assembles and worked with costomer to resolve design related issues which led to impoved yield

• Reviewed and validated supplier First Article Reports (FARs) and samples for newly sourced components, ensuring dimensional accuracy, material compliance, and adherence to engineering drawings, specifications, and customer requirements prior to production release

• Partnered with customers during prototype stage to define IQC sampling plans and inspection scope, supporting smooth transition from prototype NPI ramp-up

high volume production.

• Worked with suppliers to implement corrective actions for nonconformances, ensuring a consistent supply of materials and preventing production line downtime.

• led weekly yield meetings engineering and production teams to track products yield and drive improvements.

• Provided customer updates during ECO meetings by coordinating with supply chain, program management, manufacturing, and production teams.

• Resolved daily build issues by coordinating with engineering, customer and design teams, ensuring no line stoppages

• worked with engineering to develop fixture for product assembly

• coordinated various rework activities

• performed Biweekly process audits in the plant and drove corrective actions for the non-conformance

• Investigated enclosure scuffing and product damage for overseas shipments; implemented improved supplier packaging solutions, which significantly reduced cosmetic and transit damage issues.

• Investigated and resolved screw stripping issues on bus bar mounts by identifying root cause and recommending design changes, reducing failure rate from 33% to less than 1%.

• Worked with Engineering team to optimize the AOI programs for PCBA’s which removed redundant inspection steps and improved production throughput

• Reviewed wave soldered PCBA’s and pallet design; proposed design improvements that increased yield, reduced touch-up time, and eliminated recurring solder defects.

• Analyzed GaN FET chipping failures post-wave soldering; identified pallet design deficiencies and implemented corrective design, reducing cracks to <1%.

• Improved connector assembly reliability by developing standardized connector engagement methods and conducting periodic operator training, resulting in fewer assembly errors and higher daily throughput.

• Reviewed and optimized conformal coating program in collaboration with customer and engineering teams, updating drawings to eliminate non–value-added coating areas which reduced touchup and cycle time

• Worked with Engineerg to design a fixture for PCBA coating which reduced touch time, elimiated masking and increased throughput

• Collaborated with test engineering to develop a troubleshooting guide for EOL test error codes, enabling faster root cause isolation, recovery of failed units, and significant reduction in bone pile.

Electronics and Electrical system manufacturing/PCBA/FATP/NPI Received the Best Employee Award for outstanding performance at Sienna Corporation. Supply Chain Planner - CMP Corporation, Stone Mountain, GA /May 2022 – Nov 2022

• Managed supply chain and production planning for Carrier HVAC compressor remanufacturing operations.

• Prepared daily production schedules in a high-mix, low-volume environment to meet dynamic customer demand.

• Partnered with manufacturing and IT teams to launch new compressor models, ensuring accurate BOM setup, test procedures, and labeling.

• Collaborated with IT to identify gaps in production software and implement improvements that streamlined planning and material tracking.

• Regularly monitored backorder and shortage reports, proactively following up with suppliers to secure parts and prevent line stoppages. Engineering Intern - IKO Industries, Hillsboro, TX Jan 2022 – May 2022

• Led a line centering optimization project by collecting machine input data from HMI screens across shifts and correlating with output yield to propose optimal machine settings.

• Implemented 5S Lean Manufacturing principles to improve organization and efficiency on the production floor.

• Assisted in updating Standard Operating Procedures (SOPs), Standard Work Instructions, and One Point Lessons to align with current practices.

• Inspected plant piping layouts and updated P&ID drawings, ensuring accurate documentation.

• Analyzed data to identify major contributors to low Overall Equipment Effectiveness (OEE) and implemented corrective actions to improve uptime.

• Conducted root cause analysis on structural failure at the crusher vibrating feeder holding structure and proposed engineering design improvements.

• Updated plant equipment records in IBM Maximo CMMS, supporting asset management and maintenance tracking.

• Collaborated with line operators to enhance plant shutdown and startup procedures, improving clarity and operational consistency. Graduate Assistant - Institute of Genomics for Crop Abiotic Stress Tolerance, Texas Tech University August 2021 - December 2021

• Created research samples for data analysis.

• Implemented 5S in the IGCAST lab.

Programmer and Engineer - Applied Cognitive and Safety Lab, Texas Tech University April 2021 - August 2021

• Executed skeleton detection of humans using Intel RealSense.

• Designed a database for the Applied Cognitive and Safety Lab using MS Access. Project Engineer Trainee - WABCO INDIA LIMITED, Ambattur September 2018 - April 2019

• Implemented Lean (Value Stream Mapping) in the sales warehouse, reducing material picking and storing time by 65%.

• Designed the sales warehouse layout using AutoCAD.

• Designed a KPI dashboard for logistics and sales data using Tableau.

• Worked on an assembly line transfer project and assisted the Senior Manager in data analysis. CERTIFICATIONS:

FMEA (AIAG), IPC/WHMA-A-620, IPC-A-610H, Six Sigma Green Belt, Python, Lean Six Sigma (Data Analysis), Material Testing (NDT and Destructive Testing), Measurement System Analysis (MSA)

EDUCATION:

Master of Science in Industrial Engineering, Texas Tech University, Lubbock, TX – GPA 3.7/4 Bachelor of Engineering in Mechanical Engineering, Vel Tech University, Chennai, India – GPA 3.7/4

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