Engineer Quality Assurance

** Six Sigma Black Belt certified

** Open to Relocation

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Vijay Mani

Address: Address: 3200, Lenox Road NE, Atlanta GA 30324

Mobile: 716-***-****

E-mail: *.*****.****@*****.***

EDUCATIONAL QUALIFICATIONS

Master of Science, Industrial Engineering

Aug 2008 – June 2010

University at Buffalo, State University of New York

(CGPA:3.53/4.00)

Master of Science (Hons), Physics & Bachelor of Engineering (Hons), Mechanical

Aug 2002 –Dec 2007

Birla Institute of Technology and Science, Pilani, India

(CGPA: 7.2/10)

COURSEWORK

Linear Programming, Production Planning and Control, Six Sigma Quality, Design & Analysis of Experiments, Quality Assurance, Simulation & Stochastic Methods, Supply Chain & Global Operations, Supply Chain Design, Modeling & Optimization and Facilities design.

ACADEMIC PROJECTS

• Forecasting and Inventory Management at Campus Dining Services at SUNY Buffalo.

• Six Sigma Quality Catapult Project: Improving the tossing distance and Accuracy of the Catapult

• Developing a model for Evacuating Rockwell Shores and St. Rocks Barrier Island (A Tourist spot) during emergency using Arena

• Quality Project: Improving the flight height and flight time of paper helicopters for children

PROFESSIONAL EXPERIENCE

** Door Kraft Inc. / EcoDesign World, Atlanta GA – Supply Chain Product Engineer

Nov’10 – Feb'11

• Pricing of Raw Materials (Preparing BOM) and Cost analysis to compare Import vs. In-house prices

• Forecasting of finished goods & Raw Material order calculation.

• Assist the Design Engineer with drawings and design changes

• Identifying and Optimization of processes in the Supply Chain. (SIPOC Analysis & Cross functional work flow analysis)

• Coordinating with the QC Inspectors, Analysis & Documentation of all QC issues, root causes & corrective actions

** Osmose Utilities Services Inc., Buffalo, NY- Six Sigma Black Belt

June’09 – Dec’09

• Optimize inventory levels for raw materials and finished goods in Buffalo Manufacturing.

• ‘The Average Inventory turns’ (Sales over Average Inventory) values were as low as 1.2.

• The target inventory turns value of 3 was achieved thereby reducing the Inventory Carrying costs or Holding costs

o Define : The problem statement and Goal statement were identified with the Project team

o Measure: Identifying the trend, Seasonality in the sales and calculating the Average Inventory turns.

o Analyze: Using ANOVA and Test for Equal Variances to check for seasonality in Inventory turns values.

o Improve: Working on different forecasting methods and comparing them by error values.

o Control: Implementing the best forecasting method and implementing methods to reduce Average Inventory held also considering the Service level (ß) to avoid stock out.

• Project area/Scope: Six Sigma concepts, Project Management, Production and Inventory Management

** Reflexis Systems Pvt. Ltd., Chennai, India – Software Quality Engineer

Feb ’08 – Jul ‘08

• Web Page Design & Development using Java, JSP & SQL for retailers.

• Identifying and solving Quality Issues with the design team

** TVS Motor Company Pvt. Ltd., Hosur, India - Industrial Engineer- Manufacturing, Quality (Intern)

Jul ‘07 – Dec ‘07

• This project involved analyzing all failure modes of wheel wobbling in TVS motor bikes and controlling them.

• The Cpk values of wheel assembly were found to be around 0.7. A target Cpk value of 1.3 was achieved.

o Define: Identifying Problem statement and Goal statement

o Measure: Using process flow charts, the current process was analyzed. Gage R & R was done for instruments used for measurement. Process Capability Analysis was done to measure the current process

o Analyze: Cause & Effect diagram and Fault-Tree Analysis was used to identify all possible causes.

o Improve: Continuous improvement by making design changes working with the R&D team and making changes in process (assembly) & storage of tires (implementing FIFO). Benchmarking was also done considering the best wheel assembly in the market. Cpk value was measured for each change made both in design and the process.

o Control: Poka-yoke techniques like Dial indicator and Tire balancing machine to prevent the bad wheel assembly from entering the final assembly line. Line balancing techniques were used to reduce the lead time and also reducing the amount of scrap/rework. FMEA was implemented by calculating the RPN values along with the recommended actions

• Project area/Scope: QC tools, Root Cause Analysis, FMEA, Process Capability, Continuous Improvement, Time studies, Line Balancing, Statistical Process Control and Project Management.

** Sundaram Clayton Ltd., Chennai, India – Engineer – Manufacturing, Quality (Intern)

Jan ’07 –June ‘07

• The project involved implementing a strategy for reducing Maker’s Scrap Note Rejection (MSN Rejection) in Cylinder front and Cylinder rear castings of Visteon A/C compressor.

• The Rejection rate was found to be 8% in the cylinder parts. The target value 2% average rejection rate was achieved

o Define: Identifying the problem statement and Goal statement

o Measure: Pareto charts to determine the major defects. Process flow diagram and Control Charts were used to measure the current process.

o Analyze: Fish bone diagram to list all possible causes. 5 Why analysis was used to determine the root causes (factors that influence the defect)

o Improve: The values of the factors were constantly changed and DOE & 2-way ANOVA were used to determine those values that bring down the defect rate (Continuous Improvement technique) and to implement them. Implementing JIT in the production line to reduce WIP and to improve QC inspection.

o Control: FMEA was implemented along with the recommended actions. Control charts were used to see if the process is in control.

- Project area/Scope: Quality Assurance, Root Cause Analysis, Design of Experiments, JIT, FMEA, Statistical Process Control, Project Management and Continuous Improvement.

SKILL SET

- Highly Proficient in MS OFFICE suite tools (EXCEL, OUTLOOK, WORD and POWERPOINT).

- Working knowledge of MS VISIO and MS PROJECT.

- Basic knowledge in Auto CaD

- Highly Proficient in MINITAB.

- SIX SIGMA tools & concepts (Lean, JIT, Continuous improvement).

- Measurement System Analysis (Gage R&R), Design of Experiments, Statistical Process Control, Control Charts, Process Capability, Root Cause analysis, FMEA and other QC tools.

- Good Project Management Experience (DMAIC, Cross Functional Work flow, Gantt Charts, CPM).

- Intermediate in PeopleSoft (ERP Software).

- Basic knowledge in ARENA (Simulation Software)

- Possess good communication skills, Leadership qualities and an Enthusiastic team member.

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