Process Engineer
US Synthetic
Total years of experience :6 years, 8 Months
• Improved yields across all the factories and analyzed process data.
• Working cross-functionally with R&D, NPD, Automation and HVE teams to improve product stability and process
efficiency.
• Supported R&D group with testing and developing innovative processes to enhance product quality.
• Reduced dimensional rejects on certain products by 4 %.
• Designed changes in equipment layout to decrease cycle time and improve Overall capacity.
• Carried out Gage R&R/Measurement Systems Analysis studies to evaluate measurement variance and thereby
improve quality.
• Represented Continuous Improvement Team in the company’s annual Kaizen Fair that involved safety kaizens and
rapid testing to support the Continuous Improvement Culture.
• Carried out Operational Availability and Overall Equipment Effectiveness analysis for Master Cell PDC presses.
• Lead the SOS (Save Our Scrap) team project and monitored the project by PDCA (Plan, Do, Check, Act) and DMAIC
methodologies.
• Worked closely with Engineering, Production, Development and Quality department on Manufacturing issues and
improvement areas in Drive Unit (Powertrain) for Tesla Model 3, Model Y and Model S plaid rotors.
• Developed and modified multiple Work Instructions and ensured the production teams followed it, to reduce the
scrap making the process cost effective and reducing the manufacturing cost by 8%.
• Using Lean Manufacturing Principle, improved process by eliminating 3 non-value-added tasks across four stations,
resulted in higher efficiencies of stations on the line. Also outlined Statistical Process Control (SPC) limits across
Stations.
• Created and Documented guideline for Non-Conforming Material rework department to establish proper process
control flow by reworking non-conforming material on main production line itself.
• Practiced Root Cause Analysis with 5W and 8D approach. Successfully compiled Corrective Actions and Preventive
Actions (CAPA) to track defects occurring during final pack-out on the line.
• Performed Capability Analysis on the old parts and new sample parts to check the Variance, Standard Deviation in
the distribution and determine the control limits.
• Troubleshooted technical issues related to rotor imbalance and worked towards increasing Balancer FPY by outlining
appropriate Preventive Maintenance (PM’s) of the equipment.
• Designed and developed a fixture to hold HSK40 and BT30 collets to a high precision of within 0.0005” runout.
• Modeled the Spindle, bearings, collets, dial gauge indicator, camera equipment in SolidWorks. Created an assembly
and 2D drawings of these components.
• Researched available cameras and lenses with reasonable resolution and magnification respectively to incorporate a
machine vision system for tool defect analysis.
• Communicated with various vendors for purchasing machine vision equipment and prepared Purchase Requisition
documents.
• Tested the camera and lenses to inspect various tools ranging from 0.5 mm to 9.5 mm in diameter.
• Analyzed the tools for visual defects by creating DXF drawings and using Structure Medical’s Metlogix M3 software
thereby predicting available tool life before discarding the tool.
• Designed 3D part models with preparation of specification sheets for Elbows, Reducers, Caps, Flanges, Gaskets and
Bolting components in SolidWorks.
• Administered and maintained material specification sheets, process planning inspection sheets, BOM’s using
SolidWorks PDM.
• Collaborated with the manufacturing team to ensure manufacturability, quality, and cost reduction. Provided support
wherever necessary.
• Conceptualized Advanced Product Quality Planning (APQP), Production Part Approval Process (PPAP), control plans
and quality plan documents to direct the Master Production Schedule (MPS).
• Communicated with customers, supervisors, procurement, manufacturing, and design team to execute engineering
change requests/orders (ECR/ECO’s).
• Familiarized with Kaizen, TPS and Lean Manufacturing Principles while working cross-departmentally with
manufacturing and quality departments.