Manufacturing and Process Engineer

Jagadeesh Ancha

Manufacturing Process Engineer

Location: Frisco, TX Gmail: ******************@*****.*** Contact: +1-203-***-**** Professional Summary

Manufacturing Process Engineer with 2+ years of hands-on experience supporting new product introduction and sustaining manufacturing programs across automotive and regulated environments. Experienced in developing manufacturing documentation, implementing tooling and semi-automated work cells, and driving process improvements for electro-mechanical and electronic assemblies. Lean Six Sigma Green Belt certified, with a strong background in manufacturability and feasibility studies, cross-functional collaboration, and shop-floor execution to improve safety, quality, and productivity through data-driven engineering and continuous improvement methodologies.

Technical Skills

• Manufacturing & Process Engineering: Lean Manufacturing, Six Sigma, Kaizen, 5S, Value Stream Mapping, NPI, Process Development, Line Balancing, Work Measurement, Standard Work, Continuous Improvement, RCA, FMEA, DFM, DFA

• Automation & Controls: PLC, Allen-Bradley RSLogix 5000, Siemens TIA Portal, Ladder Logic, HMI/SCADA, FactoryTalk View, Siemens WinCC, VFDs, FANUC Robotics, Industrial Sensors & Actuators

• Engineering & Design: SolidWorks, AutoCAD, Creo, Fusion 360, Tooling & Fixture Design, Equipment Layout, Process Flow Diagrams

• Manufacturing Systems: SAP WM/MM, FactoryTalk MES, Oracle, Windchill PLM, BOM Management, Engineering Change Management

• Quality & Operations: RCCA, CAPA, Root Cause Analysis, Predictive Maintenance, Production Planning, KPI Monitoring, Safety Compliance

Work Experience

Manufacturing Process Engineer Aug 2025 – Present

General Motors Arlington, TX

• Worked on manufacturing process engineering activities supporting new product introduction (NPI) and sustaining programs, applying process development, line balancing, and feasibility analysis to enable smooth transition to production.

• Provided manufacturing documentation support by creating and maintaining assembly instructions, process sheets, BOMs, and routings, while managing engineering changes (ECN/ECP).

• Designed and implemented tooling, fixtures, and semi-automated work cells, reducing assembly cycle time by 18% and improving operator utilization by 12%.

• Performed work measurement (WM) and man-machine (MM) studies to establish standard times, optimize operator utilization, and support accurate labor planning and line balancing.

• Worked on manufacturability and feasibility studies for electro-mechanical and electronic assemblies, applying DFM/DFA, risk assessment, and root-cause analysis to resolve production issues.

• Supported production builds, trials, and equipment prove-outs by collaborating with Product Engineering, Quality, Supply Chain, and Test Engineering, including in-plant trials and validations.

• Provided data-driven quality and process improvement support using RCCA, CAPA, and Lean Six Sigma (Green Belt) methodologies to reduce variation and stabilize manufacturing processes.

• Supported shop-floor operations by monitoring safety, quality, delivery, and productivity KPIs, while driving continuous improvement, standard work, and process standardization initiatives.

• Performed Root Cause Analysis (RCA) on manufacturing defects and failures, implementing corrective actions to prevent recurrence.

• Ensured compliance with NHTSA, SAE, OSHA, and ASME standards, maintaining high safety, reliability, and regulatory adherence in automotive manufacturing.

Manufacturing Engineer Jan 2023 – Jul 2024

Tata Motors India

• Developed and integrated PLC and robotic automation solutions to enhance efficiency in body shop, paint shop, and final assembly processes.

• Led mechanical testing and validation of high-speed sortation systems for automotive logistics, ensuring seamless supply chain operations.

• Utilized Windchill PLM for managing design documentation, collaborative engineering workflows, and version control of automotive components.

• Provided technical support and troubleshooting for automated welding, painting, and assembly systems at Tata Motors’ manufacturing plants.

• Designed and optimized automated material handling systems, including conveyor belts, AGVs (Automated Guided Vehicles), and robotic arms for Tata Motors' vehicle assembly lines.

• Designed mechanical enclosures and protective housings for robotic workstations, ensuring operator safety and compliance with industry regulations.

• Developed custom fixtures and jigs to improve assembly precision, reduce cycle times, and enhance manufacturability in Tata Motors’ production lines.

• Conducted thermal and stress analysis on robotic end-effectors and conveyor components to ensure durability and performance under high-load conditions.

• Reviewed and managed engineering drawings, BOMs (Bill of Materials), and technical specifications to maintain design accuracy and manufacturability.

• Coordinated with suppliers and vendors to ensure material compliance with IS, ASTM, and Tata Motors’ quality standards, optimizing procurement and cost efficiency. Education

• Master of Science in Engineering Management.

Cumberland University - Lebanon, TN, USA 2026

• Bachelor of Technology in Mining Engineering.

Malla Reddy College of Engineering - Hyderabad, TG, India 2023

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