St. Louis, MO
SUMMARY:
Six sigma green belt certified professional adept at applying Lean manufacturing principles along with meticulous
statistical analysis to increase yield ,productivity, improve quality and profitability. Proven track record of delivering results
while working with cross functional teams. Previous experience setting up advanced manufacturing processes like LASER
welding.
HIGHLIGHTS OF ACADEMIC CAREER:
• Virginia Tech, MS in Industrial and Systems Engineering CGPA: 3.7/4.00 May 2011
• College of Engineering Pune, India: Secured 4th rank among 145 students in Bachelor of Technology program in Mechanical Engineering CGPA 8.25/10 May 2009
PROCESS ENGINEER for WATLOW ELECTRIC [August 2011 – present]:
• Equipment selection, justification and associated process design:
Procured appropriate LASER welding machine to accomplish a required welding process while working with a vendor (Miyachi Unitek). Justified the cost vs. benefits of new machine.
Co-developed a LASER welding process with supplier and ensured that the new process met a factory acceptance
test (FAT) as measured by quality, takt time and safety requirements.
• Root cause elimination and corrective action:
Worked with a team of engineers to determine the root cause of heater failure due to broken element wire.
Used metallographic microstructure analysis (according to ASTM standards E3 & E112) on defective units to arrive
at the root cause of failure. Modified the process to make it error proof (poka – yoke).
Implemented an accept/reject criteria (quality gate) for the supplied material to ensure the customer is protected
from defective parts.
• Process improvement /variation control DOE:
Set up and analyzed a 2 level full factorial DOE to determine significant causes of variation in a LASER welding
process. Used DOE results to optimize depth of weld penetration (and hence weld strength and integrity) using
suitable values for LASER spot width, pulse width, pulse power and weld location (significant sources of variation).
The improved process was under control, as evident by X bar R chart, and led to improvement in yield of around
3 % (75000 $/year savings) and reduction in field failures ( lower PPM number) for customer.
• PPAP/ APQP:
Successfully completed a PPAP to meet a product launch date while working with a team of engineers.
Responsible for data collection, G R&R, capability analysis, PFMEA on selected processes/setups.
• Fixturing / equipment modification:
Mitigated the operator induced variation, operator fatigue and improved the quality and performance of welds
by designing a fixture for spot resistance welding process.
Tested the welds performed on new fixture to meet customer defined criteria for good welds (withstand 10 lb.
axial force). Designed numerous other fixtures to improve productivity, quality and ergonomic comfort.
• Supplier yield/quality improvement:
Analyzed a critical dimension using capability study before and after casting at supplier and implemented a 3-step
solution to improve the yield at supplier:
Improved the fixture on in-house equipment to reduce the variation in the desired dimension (better Cp).
Modified the target value for the critical dimension to get better yields at supplier (better Cpk).
Introduced a new process at supplier prior to casting. These improvements increased the yields by around 5 % (
60000 $/year savings )
• Supplier evaluation/ qualific...
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