Project Quality Control

ARUN R.

Contact: +914********* / +919*********~ E-Mail: ******@*****.***

Seeking assignments in Project Management / Product Design, Development and Testing (Embedded System, Electronics and Electrical Engineering) with a growth oriented organization

BRIEF OVERVIEW

A dynamic professional with over 17 years of rich experience in managing projects and design engineering operations with key focus on top line profitability & optimal utilization of resources.

Associated with Whirlpool of India Limited, Pondicherry in Design Engineering as Deputy Manager.

Possesses a clear understanding of latest technology trends with the distinction of designing critical designs and calculations using specialised software & tools, implementing quality control techniques to achieve product excellence at the lowest overall cost.

Insightful knowledge of deploying various methodologies to analyze processes, recommending modifications to minimize escalations, reducing rejection, realizing operational efficiencies, controlling variability, costs as well as reducing the cycle time.

Demonstrated abilities in enhancing product design operations, obtaining quality certification, escalating productivity and operational efficiencies.

Resourceful in communicating feedback from the field to principals with focus on effectuating modifications in products and improving performance reducing conversion cost per unit produced.

ORGANIZATIONAL EXPERIENCE

Whirlpool of India Limited, Pondicherry in Design Engineering as Deputy Manager: Since Mar’10

Larsen & Toubro Limited (Emsys Division), Bangalore as Senior Engineer: Sep’07 - Nov’09

Pricol Technologies Limited, Coimbatore as Design Engineer from Dec’05 - Aug’07

Hi-Q System, Coimbatore as Design Engineer: Nov’00 - Aug’03

Core Competencies

Administrating project activities, handling the complete project management cycle entailing system requirement gathering & final execution of projects.

Managing project scheduling & analysis; effort & cost estimation; resource procurement, deployment & allocation.

Handling the design & development of new products, design modifications in the existing projects, supporting manufacturing during integration and testing; interacting with client and delivering projects as per scheduled milestones.

Overseeing the simulation of circuit and preparation of circuit schematic. Conducting the study of drawings, recommendations, bill of materials, classification and analysis of design change request; ensuring quality & timeliness for documentation and drawings, including documentation.

Delivering and implementing the project as per scheduled deadlines and extending post-implementation and maintenance support; finalizing requirements / with Project Owner / Engineering Departments / Collaborators and External Suppliers.

Coordinating with suppliers and reviewing the technical specifications; working out pre-ordering schedule / controlling tendering and contract finalization.

Coordinating activities for the setting-up standards with accountability for strategic utilization & deployment of available resources to achieve organizational objectives.

Interfacing with international clients (US, Brazil, Sweden and China) for quality and design related issues.

Planning effective manpower deployment & work scheduling of qualified workforce; addressing training needs of staff to enhance productivity.

Operational Purview

Strong hands on experience in:

Design & Development of Analog, Digital (8bits, 16bits & 32bits uC and uP) & Power Electronics Circuit Development and Debugging in Embedded and Real-Time Systems, Power Electronic and Industrial Automation Products, Automotive and Hybrid Electric Vehicle Drives.

Design of Industrial Controllers, Electrical Drives, Electronic Loads, SMPS and Linear Power Supplies, Inverters and Motor control Techniques with H & Hex bridges.

Testing of Industrial Electronic Products, Power Electronic Products, Laboratory Electronic Products and Consumer Electronic Products as per IEC/EN, IS and CISPR standards.

Requirement Analysis and debugging skills in Embedded and Real-Time systems, Power Electronic products, Industrial Automation Products and Hybrid Electric Vehicle.

CANopen, CAN, SPI, SCI and I2C protocols for 8/16/32-bit Microcontrollers/ Microprocessors.

Exposure to different technologies, different Hardware systems maintenance, testing the embedded software for automotive and troubleshooting.

Simulation of Electronics circuits and design with various PCB Layout tools.

Component level servicing of all type of Industrial Electronic products, Power Electronic products Laboratory Electronic products and Consumer Electronic products.

Design and Process FMEA, Preparation 8D reports for every field issues, Failure Analysis and solving the quality issues.

Software development using Assembly, embedded C for DSP, 8/16/32 bit Microcontrollers and Microprocessors.

TI, Atmel, PIC, Freescale, Intel DSPs and microcontrollers, ARM processor and FPGA.

Highlights

Recognized for the efforts & rewarded with:

“Best Performance Award - 2010” on successfully completion of VA LOW & MID Lumina Fully Automatic Washers for the year 2010.

Best Integrated Team (BIT) for "Alternate Relay Qualification Fixture" Project in Larsen & Toubro Limited for the period of 2008 – 2009

Best Appreciation on smart analysis and completion of First Prototype on “Vehicle Communication Interface (Daughter Board)” Project in Pricol Limited, Coimbatore.

Implemented many value added COST & VE projects that worth around Rs.1Crore

New Products Developed:

Regenerative Braking System.

LabVIEW based Relay Test Fixture

Vehicle Communication Interface (VCI)

XANTIA Instrument Cluster

Actively involved in implementing the process automation to check the conformal coating of the PCBs through Ultra Violet Scanning.

Significantly contributed considerable amount of cost savings in Connectors, Electronics Components, Wiring Harness and Control Components without impacting on quality in various organizations.

Successfully delivered cost saving of:

Nearly Rs10 Lakhs/annum by minimizing the PCB size and its material without affecting quality.

Product in service point of view by replacing the BTA12 Triac with ACST10 Triacs and improving the quality of inlet valve system. The inlet valve failure has been brought down to 5% from 15%.

PRECEDING TASKS

Textile Electronic Services, Coimbatore Engineer Jan’98 – Oct’00

Global Reach Software, Coimbatore Trainee cum Developer Jan’96 – Dec’97

Denmur Fax Roll Limited, Pollachi Technician Aug’94 – Nov’95

Electrical India, Nagapattinam Electrical Supervisor May’93 – Jun’94

PROFESSIONAL ENHANCEMENTS

Training Programs on:

Project Management conducted on 9 & 10th May’11.

Design for Reliability (DFR) by Whirlpool of India, at Hotel Annamalai, Puducherry in Dec’10.

“Product Hazard Management (PHM)” conducted by Whirlpool of India Limited, Pondicherry, India

Seminar “Design Compliance for EMI/EMC” conducted by Wurth Electronics at Chennai.

Simulation on Design for Safety (DFS) conducted by Whirlpool of India at Hotel Annamalai, Puducherry, India.

“Emerging Trends in Nano Technology” conducted by CII Joint with Findland NanoTech Group on 14 & 15 April 2010 at Taj Hotel, New Delhi.

Automotive Domain Expertise by SAE-INDIA (southern section) at Pricol Limited on 28 & 29th October 2006.

MSP430 conducted by Texas Instruments (TI) on 25th May, 2005.

AICTE-ISTE sponsored STTP on “An Introductory Course in Digital Signal Processing & its Applications” organized by Department of Electronics and Communication Engineering, School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore for 12 Days from 22nd November to 3rd December, 2004.

Labview 7.0 Basics organized by Department of Mechanical Engineering and CEN (Centre for Excellence in Computational Engineering) at Amrita Vishwa Vidhyapeetham, Coimbatore – Feb’ 2005.

Hardware, Networking and CCNA program at IIHT, Coimbatore.

Workshop on “Biomass Gasification technology for Power Generation” on 6th Mar’04 organized by the Industry Institute Partnership Cell, The National Institute of Engineering, Mysore.

Licensed Member for Amateur Radio (HAM Radio License No: 31153, Call Sign: VU3RPJ).

TECHNICAL PURVIEW

Hardware Platforms:

TI DSP TMS320F28xx, iMx31-ARM11 Processor, FPGA EP3C25F324C8 & ECU MPC555.

Freescale DSP56F807, PIC 18F/24F/30Fseries, Intel 80C31, 80C51, Atmel’s AVR Series and 89C52 Microcontrollers, Fujitsu MB95F176J (CS) 8Bit Controller.

CAN, SPI, SCI, RS232 and RS485/RS422 Driver.

TFT and LCD Displays, Key Boards, Touch Screens, RAM, SDRAM, Flash, EPROM, EEPROM, Buffers, Latches, Decoder, ADC, DAC, Op-Amps, Sensors, RTC and Relays.

Tools:

OrCAD/PSICE, LTSpice, PCAD 2005, Dx Designer-Mentor Graphics, Protel 99SE, Microsim

Visual Source Safe (VSS), PVCS(SERENA VM), MKS Bug reporting system, MS Office utilities, MS Project, MS Visio, Windchill

CANCardXL, CANCaseXL, NI-DAQ Card, Logic Analyzers, Oscilloscopes/Digital Storage Oscilloscope(DSO), Function & Pulse Generators, Spectrum Analyzer, Power Analyzer

MATLAB /Simulink 6.2, CANoe, ProCANopen, LabVIEW 8.0 basics

MPLab IDE with C30, C18 compiler and Quartus II Simulation Tool, AVR Studio, A51 Assembler, Hi-tech PICC Compiler, Keil Compiler, Metrowerks Code Warrior, CodeWright, IAR EW

Software Platforms:

Assembly Language for Intel 80C31, 80C51, Atmel 89C52 Microcontroller.

CAPL (CAN Access Programming Language)

C language for 8031, 8051, 89C52, ATmega128, AT90CAN128, PIC uCs, Fujitsu MB95F176J

Protocols:

CANopen & CAN

I2C, SPI, ISO9141 K-Line & L-Line, KWP2000, SCI- RS232, RS422 / RS485

Operating Systems:

Windows 9x/Me/XP/Windows 7 and MS DOS 6.0

Standards:

IEC Standards for EMI, EMC, ESD, CISPR, Intrinsic Safety Standard (BS EN 60079-11:2007), UL and CSA Standards.

IPC Standards for PCB Manufacturing.

Testing in Product Reliability Assurance (PRA) Lab.

SAE J1939, ISO 11898, ISO 9001 and ISO 15288 Standards.

ACADEMICS

M.Tech. (Computer Application in Industrial Drives-CAID/EEE) from National Institute of Engineering, Mysore, VTU-Belgaum in 2005 with 72%.

B.E. (Electrical & Electronics) from Government College of Technology (GCT), Coimbatore in 2001 with 68%.

D.E.E.E. (Electrical & Electronics Engineering) from State Board of Technical Education, Tamil Nadu in 1993 with 79%.

ACADEMIC PROJECTS

Micro Controller (ATMEL 8051) based Temperature (230V AC) & Level Controller using Fibre Optic Cable.

Industrial Training in Mighty Electronics Equipments Corporation Limited.

Four Quadrant DC Chopper Drive using DSP Controller (DSPIC30F2010) for 230VDC Shunt Motor

PERSONAL DETAILS

Date of Birth : 6th March, 1974

Present Address : No. 28, First Main Street, Velmurugan Nagar, Kosapalayam, Puducherry - 605013

Languages Known : English, Tamil, Kannada and Malayalam

Passport No. : H3167180

HSMP Visa No. (Tier 1) : 9IND7403068M1305056

ANNEXURE

Fully Automatic Washer Lumina L1-L5 (Global Project)

Team Size 15

Role & Responsibilities

• Responsible for delivering the Entire Hardware deliverables

o Undertaking complete ownership for the product.

o Attributes finalization for various region across the globe

o Defining India’s requirement and update in the global document

o Updating the control system specification, Module finalization, Preparation& design assistance for all the Hardware section.

o Preparing 8D report, safety and Control FMEA for all control components

o Checking the circuit compatibility for all the region through circuit simulation

o Reviewing of Components placement and Routing

o Support and process audit for PCB fabrication and assembly with vendor.

o Verify wiring harness for the entire system

o Performing various safety, environmental and EMI/EMC tests

• Maintaining the software deliverable with respect to the predefined time line

o Co-ordination in preparing the Software requirement specification

o Review of SRS, Software Design document, co-ordination for algorithm development, review of Unit test plan and system test plan.

• Software Quality Control

o Preparation of global integration test plan dedicated to software Quality

o Follow up with SQC team for issues during Manual testing (Black box testing)

o Uploading the issues in MKS System and monitor the status on daily basis follow up with required reviews

• Product Quality control

o Monitor the failure of Electronics components, control components and software bugs from field data and PRA Lab data.

o Preparation Quality action tracker for regular follow up the entire cross functional team to address the failure in the next phases of the project.

Synopsis This is a cost driven Global project for LAR, NAR, China, Europe and India, mainly focusing on quality and cost. Advance control algorithms involved with Current and voltage sensing of all the control components along with the Phase Split Capacitor type Motor of 230VAC, 5A is controlled by ACST10 Triacs. The major milestone of this project is Auto diagnostic that has sensing of each and every module through proper voltage and current sensing methodology. Inlet Valve, Torque Motor, recirculation pump, Drain Pump and Heater(1450W) which are rated for 230VAC and the working range of 170V – 270V. This project has some additional features like Tub Light and Slot Sensor Technology called 6th sense (balanced load condition). Cost savings also includes minimization of PCB size. This project is under completion stage.

Fully Automatic Washer – Quartz

Team Size 10

Role & Responsibilities

• Responsible for delivering the Entire Hardware deliverables

o Undertaking complete ownership for the product.

o Updating the control system specification aligned

o Preparing 8D report, safety and Control FMEA for all control components

o Module finalization, Preparation& design assistance for all the Hardware section.

o Checking the circuit compatibility for all the region through circuit simulation

o Reviewing of Components placement and Routing

o Verify wiring harness for the entire system

o Performing various safety, environmental and EMI/EMC tests

• Maintaining the software deliverable with respect to the predefined time line

o Co-ordination in preparing the Software requirement specification

o Review of SRS, Software Design document, co-ordination for algorithm development, review of Unit test plan and system test plan.

• Software Quality Control

o Preparation of global integration test plan dedicated to software Quality

o Follow up with SQC team for issues during Manual testing (Black box testing)

o Uploading the issues in MKS System and monitor the status on daily basis follow up with required reviews

• Product Quality control

o Monitor the failure of Electronics components, control components and software bugs from field data and PRA Lab data.

o Preparation Quality action tracker for regular follow up the entire cross functional team to address the failure in the next phases of the project.

Synopsis The main aim is to replace the Linear Power Supply with SMPS to avoid the field failures. Triac analysis for the replacing Triacs along with layout change, and modification on Heater power rating. Phase Split Capacitor (PSC) type Motor of 230V, 5A is controlled by BTA12 Triacs. Along with this, Inlet valve and Torque Motor which are rated for 230V are controlled by Relays. Due to continuous failure of few components like inductor, power resistors etc, a complete analysis has been taken out solve all the issues. Reduction in PCB size also played an important role to minimize the cost of the product.

This project is also addressed the Inlet valve failure issue at the field. Now total the failure rate for the product has been brought down from 15% to 5% with a good cost saving.

Regenerative Braking System for Electric Bicycle

Team Size : 3

Role & Responsibilities

• Understand & Analyze the system level requirements

• Preparation of Requirement Specification and Design Documents

• Simulation of Circuit and Preparation of Schematic

• Preparation of BOM and procurement of components

• Involved in Components placement and Routing

• Preparation of System Test plan and carry out System testing

Synopsis The Regenerative Braking System mainly consists of BLDC Motor, 4x12V Batteries to run the motor, 3Phase Inverter, Bi-directional Buck-Boost Converter, Gate driver circuits and PWM Isolation Circuits, and power supplies. The back EMF from the BLDC motor is temporarily stored in Ultra-capacitor, when the vehicle is in downward direction where the vehicle speed is controlled.

When the vehicle is moving upward direction, the energy stored in the Ultra-Capacitor is pumped to the DC bus to accelerate the BLDC Motor. When the vehicle is in downward direction, the BLDC motor acts as generator and the energy is stored in ultra capacitor. The 56F807 DSP is used to control all the system operation. The controller shall have all the necessary IO pins, Timers, PWM modules etc to control the power module.

LabVIEW based Relay Test Fixture

Customer Kidde Fenwal, North America

Team Size : 3

Customer : Kidde Fenwal, North America

Role & Responsibilities

• Played a very important role for the entire project

• Complete Hardware design for Relay mounting board and Relay Interface Card

• Pin assignments for 10 Digital Input for generating pulsed input 10 relays.

• Pin assignments for 20 Digital outputs and 2 Analog outputs of NI-DAQ card

• Development of Software Algorithm.

• Component selection and preparation of BOM

• Test the product after integrating the software with hardware.

• Preparation of System Test plan and carry out System testing

• Failure rates of Relays are predicted with Weibull Analysis

Synopsis This is a development project used to test all kinds of power relays (Electro-Mechanical) supplied by the customer. This is an automated testing to test 10 relays at a time, using LABView Automation. The Electrical Endurance characteristic of the relay is the main parameter to be tested for its rated load. Other parameters of the relays like Contact Resistance, Coil Resistance, Insulation Test, Breakdown Strength, Jarring Test, etc. were also tested. The maximum power rating (7.2KW for the relay tested was 240V, 30Ampere. Weibull prediction is involved in this project.

Automated Software Testing - 23PV Test and Stark

Customer : Danaher Motion, Sweden

Team Size : 4

Role & Responsibilities

• Understanding the requirement as Module-Wise

• Study & Usage of CANoe, ProCANopen, CANcaseXL

• Deriving various test cases for each module

• Writing CAPL scripts for all the Modules

• System testing

Synopsis This is software Automated Testing for existing software in Engine Control Units (ECU-Hardware) for the Volvo trucks. Testing of software is done through CAN communication by writing CAPL (CAN Application Programming Language) using software tool as CANoe and ProCANOpen. Various test cases are developed for various modules in the ECU and the HTML report is generated displaying the result status.

Vehicle Communication Interface (VCI)

Customer : SPX Service Solution, US

Team Size : 10

Role & Responsibilities

• Understand and Analyse the Customer requirements

• Design of Daughter Board which is used to interface the processor board with vehicle.

• Development of FPGA Evaluation board.

• Selection of Components & Preparation of BOM.

• Widely involved in Schematic, Placement & routing using Dx-Designer.

• Preparation of System Test plan and carry out System testing.

Synopsis The communication between Processor board and the vehicle is taken by the board called as Daughter Board. It has 3 major sections viz. FPGA, Transceivers and Switch Matrix. The various communication Protocols/Transceivers like High Speed and 1wire CANs, ISO 11992, ISO 9141 K-Line & L-Line, Mitsubishi PCS, CCD, SCI, SCI Transceiver, Nissan DDL Clock, DCL 1708, and Multi Transceiver Circuits are widely involved in the hardware design. The output from the processor is connected to a 100 pin connector. The output of daughter board ended with 25pin DSUB vehicle connector from which the communication happens to the vehicle. Functional verification of the complete vehicle is done by VCI handheld device through various communication protocols

XANTIA Instrument Cluster for Four Wheeler using Fujitsu MB90022 (16 bit)

Customer XANTIA

Team Size 4

Role & Responsibilities

• Understand Customer requirements

• Development of Hardware design and Simulation of Circuits

• Selection of Components & Preparation of BOM

• Development of system test plan and carry out System Testing

Synopsis Cluster consists of Cross coil based Speedo meter, Tachometer, Fuel Gauge and Temperature Gauge (Cross coils Driven with PWM). A LCD based OdO meter and TRIP display are provided to monitor the distance. Low Fuel Warning, High Temperature, High-speed warning, ABS, Door open and Park-break (Buzzer) are also implemented in this design.

Discover-JD Digital Instrument Cluster

Customer M/s Bajaj

Team Size 3

Synopsis It has a Stepper Motor based Tacho, and an LCD which displays Speed, Odo, Trip, Fuel and an indication for Low Battery. It also has LED Display for High Beam, Turn, Neutral and Low Fuel. As a user interface a reset switch is available for resetting the Trip. 12V and 5VDC power supplies are driven from vehicle Battery. It employs a unique power saving option, which turns off the display automatically, if inactive for sometimes.

Variable Speed Drive using Universal AC Motor(0.5KW) for Vacuum Cleaner

Synopsis There are 4 variable speeds viz Low, Medium, High and Turbo for controlling the universal AC Motor. Triac BTA12-HS is used as power device for controlling 230V AC through phase control Technique. An over load protection using thermal switch for the Motor is employed in case of overload. It has built up with Soft start Implementation.

Rice Sorting Machine

Synopsis Implemented the design for sorting out of Black rice and brown rice from the various chutes using photo diode array of 128pixels to sense the rice color. Deploying Op-Amp based analog circuits to amplify the signals from the sensors.

Screen Printing Machine

Synopsis Two heads are employed: Squeeze head and print head. Both the heads will move both the axes according to the algorithm. 12V dc motor is used for controlling both the heads

Other Modules Designed & Constructed SCR, MOSFET and IGBT based Power Electronics modules:

Buck Boost Converters and Inverters.

5V SMPS and 12V & 24V Power Supplies

230V AC Voltage Controllers (0.4KW) using Phase Control Technique

230V AC, 1KW Solid State Relay by Zero Volt Switching Technique

40V AC Series Inverters, Single & Four Quadrant 220V DC Chopper using IGBTs & MOSFETs

Other Projects & its related activities

Design & Development of Universal Counter & Timers for Textile Machines

Design & Development of 230V AC Universal Motor Control

Design & Development of H-Bridge Inverter for 12V DC Motor

Maintenance & operation of Electrical and CNC based Machineries.

Control and Maintenance of 220V DC Thyristorized control converter panel for Power Electronic Drives.

Substation Maintenance for 11KV/440V & Maintenance of 500KVA Distribution Transformers, Switch Gears, lighting circuits and laying of U.G cables

350 KVA DC set and other Electrical Machineries & Equipments maintenance

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