Six Sigma Black Belt
General Electric
Total years of experience :26 years, 4 Months
Lean Six Sigma Black Belt (DFSS) - Advanced Technology and Engineering
Key Achievements:
• Driving Six Sigma culture - Achieved a business value add of $400M, through mentoring 30+ DMAIC/DFSS projects across GE Oil & Gas business (Asia-Pacific Region) - Jan-Dec 2015
• Six Sigma Mentoring: Achieved an increased rate of Six Sigma projects closure (25+ GB DMAIC/DFSS certifications) through a structured review process and periodical follow ups. Reduced the number of Six Sigma certification backlogs by developing an effective tracking mechanism. Created and maintained an increased quality rigor through internal/external ISO audits, The Way We Work-Engineering initiatives, and regular awareness sessions on QMS.
• Process Simplification - Saving ~900 hrs TT/year and 70 days CT/project, saving 100 k$/year through leading Lean Action Workouts and Kaizens.
• Process improvements - Improved the software based performance predictability of turbo-machinery components, help reducing the number of mandatory physical tests, leading to savings of the order of $100M/year.
• Lean Six Sigma Coaching - NPS score ~100% (above GE average) for the Lean Six Sigma training for both DMIAC & DFSS streams (coaching 100+ GBs/Year). Enhanced the course effectiveness by developing and updating the course material for both DMAIC & DFSS courses.
• Strategic Road Maps: Enhanced engineering and design productivity through development of new/modified design/analysis tools. Created and owned the strategic road map for engineering tools development to improve the team’s design and performance prediction capabilities.
• Root Cause Analysis: Ensured recurrence of the business critical GT Firefighting Skid issue (Business Impact of $300K), through implementation Corrective & Preventive Actions, after a structured RCA methods, involving external suppliers.
• Centrifugal compressor Design - Achieved >50% improvement in the centrifugal compressor side-stream plenum performance through an effective optimization and validation strategy. Helped the project team to derive statistically relevant conclusions for a relatively complex project, comprising of 12 CTQs & 15 Design Variables, through use of Six Sigma methodologies and statistical tools. Achieved successful passing of different tollgates by developing novel analysis strategies.
• Compressor Performance Predictability: Improved the compressor performance prediction capability by partnering with the tools development team, to help both NPI & Requisition activities by reducing the dependence on physical model tests. Used six sigma tools effectively for a statistical deep dive into predictability data.
Engineering Technical Leader - Advanced Technology and Engineering
Key Achievements:
• New Product Introduction (NPI) projects helping business to capture the LNG compressor market share: 1. “High Head Stages” to increase pressure raise per stage through aero design modifications, 2. “Vaned Diffusers”, to increase the compressor stage efficiency, and 3. “Movable Tandem Diffuser Vanes” to increase compressor operating range, all employing Six Sigma concepts and use of statistical methods.
• Achieved higher compressor stage efficiency without compromising operating range by adopting the DACE based optimization methodology.
• Design/analysis process simplification: Increased the team’s productivity (reduced analysis time from 5 days to < 2 days) by developing software tools and macros and ensured an error free execution through automated internal pre/post-processing methods and tools.
• Improved the quality of analysis process by developing the best practice for CC stage CFD, using a statistics based approach.
• Improved/created new CC CFD modeling methodologies, analysis/design tools and created awareness of the available existing tools by acting as a technical focal. Developed the analysis tools road map to help faster and robust performance prediction.
• A number of ideas resulting in new products/improvements by conducting innovation & competitive technology analysis (CTA) sessions.
• Improved the knowledge sharing across teams by conceptualizing and leading Technology Knowledge Sharing Forums involving senior controlled title holders& business leaders, sharing best practices and technological advances.
Awards:
• Won the Global “Six Sigma Project of the Month Award” from GE Oil & gas Quality Council in 2014, for one of the DFSS green belt project mentored and fished in 2nd / 3rd place for all the projects (5 in total) presented.
• GE Energy/Oil & Gas ERD Awards:
1. Technology Excellence - 2011, for Centrifugal Compressor Stage Development activities
2. Process Excellence - 2013, for compressor stage performance predictability improvement activities
• International Patents:
1. “Novel radial diffuser vane for centrifugal compressor” - 2009
2. “Tandem moveable IGV for return channels” - 2014
Assistant Manager - Computer Aided Engineering/Analysis
Key Achievements:
• Captured industry wide recognition to the CFD analysis capabilities in Larsen & Toubro limited during early 2000s by developing the teams capability in various analysis domains, such as complex geometries, multi-phase flows, steady/unsteady calculations, combustion and heat transfer modeling and turbo-machinery simulations.
• Compressed the analysis cycle time through innovative analysis methods, meshing and chunking strategies.
• Converted many mandatory test requirements into CFD/FEA based analysis to the full satisfaction of customers & project management consultants such as EIL, TCE, etc.
• Establishing the CFD analysis team for L&T’s E-Engineering Solutions Business. Key customers served include, Carrier Corporation-USA, Chiyoda Advanced Solutions-JAPAN, AUDCO, etc.
• Resolved business critical engineering problems through analysis solutions for process and power plants, such as “Fired Heaters”, “Process Reformers”, “Flow Control Valves”, “Cooling Water Intake Sumps”, “Scroll & Screw Compressors”, etc.
• Ownership in developed structural design and analysis capabilities for Fired Heaters, a process plant equipment.
Pre and post sales support of Autodesk product suite such as AutoCAD, Mechanical Desktop, etc. Familiar and hands on experience with most of the leading CAD/CAM solution software.
Supported sales team in winning many orders from the research and development organizations including VSSC, LPSC, DRDO, etc. and universities.
Teaching Mechanical Engineering subjects to undergraduate students.
Project Work: Free Vibration Analysis of Unsymmetrically Laminated Curved Composite Beams A finite element code was developed for the free vibration analysis of the unsymmetrically laminated curved composite beams. Code was validated against the experimental results from literature and found a good match. The development work carried out as part of research activities of Indian Space Research Organization.
Project Work: Title: Experimental Modeling of Pump as Turbine Concept. Pump as Turbine concept is developed to help small scale hydro-electric (Micro-Hydal)projects. An experimental test rig is developed as part of this project, a scaled down model of the concept is created and the performance map for different operating conditions generated. This project helped the Integrated Rural Technology Center (IRTC), Plakkad, Kerala, in selecting the technology for the MIcro-Hydal projects.