Manufacturing/Process/Quality/Product/Industrial/Operations Engineer

SUMMARY OF QUALIFICATIONS

Adaptable, hands-on and communicative Engineer with a Masters in Mechanical & Aerospace Engineering

Experienced in Consumer, Commodity and Automotive Manufacturing environments in deploying Quality

Assurance, Lean Manufacturing and Six Sigma methodologies

Well-versed with Lean-Six Sigma, Manufacturing, New Product Design, Research and Development

Six Sigma Greenbelt DMAIC and DFSS trained

PROFESSIONAL EXPERIENCE

The Trane Company, Ingersoll Rand – Trane Commercial Systems, Clarksville, TN 2007–Present

1500-employee, $400 million manufacturer of HVAC products

New Product Introduction (NPI) Engineer

• Administered design, analytical and floor-level engineering support

• Team member for mandatory refrigerant conversion projects (from R-22 to R-410A)

• Surveyed internal and external customers for design inputs; specified, designed, verified and supported production launch of new HVAC product programs per customer requirments

• Used Design for Six Sigma (DFSS) tools to evaluate safety, reliability, quality, cost, and performance compliance and/or standards

• Collaborated with agency personnel for commercial HVAC unit UL (Underwriters Laboratories) compliance

• Implemented Six Sigma Greenbelt DFSS projects successfully

o Refrigerant Charging Process Poke-yoke

 Re-designed the system to accommodate access valves (Schrader valves) for refrigerant charging to reduce compressor failures

 Potential reduction of service costs by $12,000 annually

 Annual cost avoidance of $30,000

o Access Valve Cap Re-design

 Redesigned system access valve cap to reduce unit leak rate and manufacturing lead time

 Potential reduction of service costs by $8,000 annually

 Annual warranty cost avoidance of $23,000

• Conducted design and manufacturing prototype builds – created and executed verification plans, tests and related documentation

 Monitored daily build issues and used DFSS tools to resolve / re-design the prototypes

 Led the mandatory R-410A refrigerant conversion for a commercial unit, Voyager II

SaarGummi Tennessee – Pulaski, TN 2006–2007

200-employee, $5 million manufacturer of Rubber Automotive Sealing Systems

Process Engineer

• Provided floor-level & systems-focused Engineering support for a Tier I automotive supplier of Rubber Sealing systems for Mercedes Benz

• Activities mainly devoted to – daily production troubleshooting, Pull system design and implementation, problem-solving, productivity improvements, Six Sigma, 5S and other Lean Manufacturing initiatives

• Managed eight indirect reports

• Kanban – Pull System Design & Implementation:

 Designed & implemented plant-wide Finished Goods and Work-In-Process Pull system for all rubber sealing products

 Collaborated cross-functionally with Production, Materials and Sales groups and executed the project in liaison with The Kaizen Institute

 Conducted hourly and associate training on Pull System concepts and Kanban implementation

 Service levels improved by 30%, 1000 annualized labor hours were reduced and finished goods inventory was stabilized at 3 days, resulting in a net cost savings of $80,000

 Partially implemented Raw Material pull system

• Process Flow Optimization (One-Piece Flow):

 Optimized cellular layout for a low volume finishing cell

 Conducted Time & Motion studies and used Spaghetti diagrams to baseline current state

 Opportunities identified resulted in 30% reduction in operator movement and 20% increase in bottleneck efficiency

 $30,000 annualized cost savings and cost of failure reduction

• Scrap Reduction (Six Sigma Greenbelt DMAIC Project):

 Lead to a potential process modification to reduce scrap, downtime and cost of failure of a Glass Run Flocking process with high-precision Robotic Glue-application and Plasma-treatment systems

 Conducted Measurement Systems Analysis (MSA) and Design of Experiments to draft equipment specifications and target key deliverables to align with the organizational goals for a Return on Investment of less than 6 months

 Identified improvements to generate $40,000 annualized cost avoidance

• 5S Deployment:

 Conducted a comprehensive 5S training in strategic manufacturing cells

 Program was extended plant wide

Newell Rubbermaid – Office Products Manufacturing / Distributing Plant, Lewisburg, TN 2005–2006

350-employee, $80 million manufacturer of writing instruments

Continuous Improvement Engineer

• Activities primarily involved daily production support and driving change through Six Sigma and Lean Manufacturing initiatives

• Worked on productivity projects to reduce product cost through reduction of scrap, downtime, cost of failure; to eliminate non-value added operations and optimize material flow

• Participated and led Kaizen events: TPM, Changeover (SMED), Standard Work, Metric Implementation

• Lean Manufacturing Tools Used: Value Stream Mapping, Spaghetti Diagrams, Visual Systems, Standard Work, 5S

Quality Engineer

• Provided plant-wide Quality control support

• Performed Supplier Qualifications and Specification formulation for injection molded plastic parts

• Formulated and implemented Standard Operating Procedures

University of Missouri at Columbia – Columbia, MO 2002–2005

Graduate Research Assistant

Thesis Title: Mechanical and Thermal Buckling of Thin Films (A National Science Foundation funded project)

• Researched thin films for Micro-electro mechanical system component design; conducted Structural Analyses – stress, thermal and modal analyses using Finite Element Analysis and tools like ALGOR, ANSYS and I-DEAS

• Validated results with simulations and established relationships between force, thermal stresses, and natural frequencies of structures

EDUCATION

Master of Science in Engineering Technology & Industrial Studies (incomplete)

Middle Tennessee State University, Murfreesboro, TN; 2006-2007 GPA: 3.7/4.0

Master of Science in Mechanical & Aerospace Engineering

University of Missouri – Columbia, MO, July 2005 GPA: 3.33/4.0

Bachelor of Technology in Mechanical Engineering (Mechatronics)

Jawaharlal Technological University, Hyderabad, Andhra Pradesh, India, June 2000 GPA: 3.6/4.0

TRAINING

• Six Sigma Greenbelt DMAIC (Middle Tennessee State University Course)

• Six Sigma Greenbelt DFSS (The Trane Company, Ingersoll Rand)

• Lean Manufacturing (Middle Tennessee State University)

• Refrigeration Fundamentals (The Trane Company, Ingersoll Rand)

SOFTWARE & CAD/CAE SKILLS

MS Office; MINITAB 14; MATLAB 6.1; Simulink; C; C++; Java 1.2; FORTRAN; PASCAL

AutoCAD 2006; ALGOR V14; ANSYS 6.0; Solidworks 2005; Pro/ENGINEER Wildfire 2.0; I-DEAS 9.0

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