Mechanical engineer experienced in Quality/Process area.

Highly skilled and dedicated Mechanical engineer seeks to utilize skill in process improvement and quality control in a challenging manufacturing environment.

SUMMARY:

- 4 years experience in key role as Process Capability Analyst for Ford Motor Company with in-depth knowledge in dimensional control, measurement systems, SPC, statistical analysis, gages, fixtures, 8D problem solving, DOE, FMEA, DFM/DFA,GD&T, QS 9000/TS 16949 and assembly tooling.

- Strong quality background with in-depth understanding of APQP and PPAP processes.

- ASQ Certified Six Sigma Green belt with experience in implementing Six Sigma tools.

- Exceptional organizational, analytical and problem solving skills with thorough understanding of lean manufacturing, Value Stream Mapping, 5S and Poke Yoke.

- Excellent mechanical aptitude backed by Bachelors & Masters degree in Mechanical engineering.

- In-depth design/development experience with expertise in using various FEA/CAD softwares.

PROFESSIONAL EXPERIENCE:

Ford Motor Company, Chicago, Illinois

June 2005 to Sep 2009

Process Capability Analyst (Contract)

- Effectively employ statistical analysis to uncover and resolve root causes for various process, quality, and dimensional issues occurring in the assembly plant body shop during new vehicle launch programs.

- Trouble shoot daily data flow problems using expertise in numerous measurement devices (CMM, Vision, Laser gauge) and computer skills (CM4D, MS Excel, Minitab).

- Implement and follow up on containment action, interim/permanent corrective actions using Ford 8D problem solving methodology.

- Work with Design engineers/Supplier technical assistant to resolve all design/supplier quality issues.

- Support periodic review and update of PFMEA, process charts/visual aids.

- Ensure all sheet metal parts pass Gauge R&R and drive gauge selection and development.

- Identify new quality improvement opportunities by reducing variations between different assembly lines.

- Create Comparison, Box Plots, Benchmark and Prioritization Matrices for management review.

- Evaluate the consistency of locators through the manufacturing, assembly and gauging processes.

- Utilize Vis View/Catia V5 to cut sections of the assembly to understand design intent.

- Act a liaison between Dimensional Control and Body Construction departments and using Six Sigma to improve the working of the overall process and in the development of new standards.

- Ensure all body shop processes have proper error proofing techniques in place for easy error detection.

- Assist in the creation of production control plan and ensure that frequencies and checks are adequate for ongoing production.

- Maintain Tooling shim log for all areas until the end of launch and deliver it to the plant.

- Ensure all measurement systems have acceptable correlation (CMM, Vision systems).

- Conduct DOE study to determine the relationship of factors affecting the process output.

- Maintain issue matrix to keep track of all open/pending/closed issues for the launch.

- Perform complex engineering calculations to verify design requirements.

Accomplishments

- Played a pivotal role in the quality improvement of the new 2010 Ford Taurus body.

- Performed exceptionally well in every launch program.

- Improved the data reporting process using six sigma saving $10,000 per launch (40% savings).

- Teamed with manufacturing engineers to improve their tooling system capabilities and helped them achieve process capability (Pp & Ppk) > 1.33.

- Trained plant Managers/Operators in SPC, Statistics and Quality Principles.

University of Michigan, Dearborn, Michigan

Jan 2004 to June 2005

Research Assistant

- Designed and developed a car bucket seat frame applying numerous technologies such as Structural Optimization, Parametric Modeling, Design of Experiments (DOE), Finite Element analysis and complex simulations.

- Utilized various FEA & CAD software applications such as Optistruct, LS-DYNA, Hypermesh, Pro E and Catia V5.

Accomplishments

- Achieved/implemented significant savings in both design time and mass (20% reduction).

- Successfully design and developed a lightweight automotive bucket-seat frame, employing a novel parametric design approach.

Arvin Meritor, Detroit, Michigan

Sep 2003 to Dec 2003

Intern

- Collaborated with designers, providing input regarding “roof system” concepts.

- Devised solutions to meet overall assembly of roof module per design.

Accomplishments

- Successfully evaluated feasibility of new design concept within Arvin Meritor manufacturing parameters.

- Resolved roof module water management issues and devised sunroof mechanism.

EDUCATION:

University of Michigan, Dearborn, Michigan

Dec 2006

Received Master of Science degree in Mechanical Engineering

Bangalore University, Bangalore, India

Sep 2001

Received Bachelor of Science degree in Mechanical Engineering

TRAINING & CERTIFICATION:

- American Society of Mechanical Engineers (ASME) - Lean Manufacturing

- ASQ - Six Sigma Green Belt Certification

- Quality Associates International - APQP

COMPUTER

SKILLS:

MS Word

Team Center

MS Excel

Abaqus

MS Visio

Catia V5

Pro E

SDRC-IDEAS

Hypermesh

Auto CAD

LS-DYNA

Minitab

CM4D

Power Point

Outlook

MS Access

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