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<pre>Array ( [var] => cut_url ) </pre> Resume for Rahul I. for Engineer / Manufacturing in Mesa, Arizona. Search More Resumes for Engineer on #UQIDSYOKJ

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Resume for Rahul I. for Engineer / Manufacturing in Mesa, Arizona

Occupation: Engineer Industry: Manufacturing
Country: United States City: Mesa
State: Arizona ZIP: 85213

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U.S. Citizen

East University Drive, Unit , Mesa AZ

Tel: , Mobile: 


Looking for long term opportunity in process improvement & development.  Trained in Six Sigma Black Belt & Toyota Production Systems, experience in product/machine/fixture design, and review of new trial parts.  I have lead people, and resolved issues, improved productivity, increased profit, and generated new business utilizing process improvement.  Demonstrated history of leading process improvement, meeting stringent customer expectations, and ultimately resulting in cost savings.   


  • Lead production plant, total of people in Value Stream Mapping & establishing a Rapid Baseline among lines of Dana Production Systems DPS. Total of Black Belt opportunities identified, kaizen opportunities identified
  • Lead Six Sigma projects, consisting of people each, average US$K savings per project annually
  • Lead kaizen activities, consisting of to people each, average US$K savings per kaizen annually
  • Supplier development initiatives, consisting of people and + suppliers, average US$K savings per initiative annually
  • Value Analysis/Launch Initiatives, consisting of people and suppliers, average US$K savings per initiative and US$. million dollars in new sales annually
  • Mentored, Supervised, and trained people in process improvement, kaizen, and Six Sigma.  Two went on to become Six Sigma Green Belts
  • S Introduction, Education, and Initiatives, consisting of people, Increased availability in Wax Injection by %.  Supervised people in Wax Injection and Wax Assembly process
  • Supervised two Maintenance technicians.  Assisted and Mentored them in development of Total Productive Maintenance TPM Program.  Improvement in machine availability by % on an annual basis


    The Landmark Forum, Sep

    Landmark Education, Chicago IL 

    Master of Science in Engineering MSE, Mechanical Engineering, Dec

    Western Michigan University, Kalamazoo, MI 

    Bachelor of Science in Mechanical Engineering, Area Minor in Biomedical Engineering, May

    RoseHulman Institute of Technology, Terre Haute, IN

  • Quality Intern, Medline Industries Inc Mundelein IL
  • Supervised temporary workers for rework of material workers spoke only Spanish
  • Documentation for FDA GMP & Design Control


    Six Sigma Black Belt Certification, Aug

    Dana University Technical School, Ottawa Lake, MI

    Internal Auditing to the ISO/QS Quality Standard, Jan

    Tooling & Manufacturing Association, Park Ridge, IL 


    English native,  Spanish proficient, Vietnamese beginner, Russian rudimentary, TamilIndia rudimentary 


    Continuous Improvement, Toyota Production System TPS, Classical Design of Experiments

    DoE, Taguchi Methods, Shainin’s Methods, FMEA DFMEA & PFMEA, Gage R&R

    QS /QS /AS , ISO /TS /ISO , Nonparametric Statistical Methods & Parametric Statistical

    Methods, Root Cause Analysis, PERT/CPM, A Methodologies, WhyWhy Analysis/Fishbone/ Why Analysis, D,

    Metrology Techniques 


    Optical Methods, Thermal Design, Metallurgy Stamping, Casting, Forging , Machining, Deep Drawing 


    Geometric Dimensioning & Tolerancing GD&T, CP, AutoCAD, Mechanical Desktop, CADAM, CADkey,

    Pro/Engineer, SDRC IDEAS Master Series, Alibre Design, Solidworks


    C++, FORTRAN, Microsoft Windows, Microsoft Office Excel, Word, Access, PowerPoint,  Lotus ,

    WordPerfect, Motorola / Assembly Language, MINITAB, Primavera, MS Project, Maple VR,

    MathCAD,Visio, SmartDraw, SAS 


    Quality Engineer & Supplier Quality Engineer, automotive

    Tepro Industries Inc, Winchester TN

  • Downsized out of job due to economic situation
  • Championed system to manage and track quality of suppliers including PPM, with assistance of Purchasing, Production, and others reduced supplier related PPM by %
  • Reviewed, revised, and developed Standard Work Instructions SOPs, Control Plans, Quality Standards, and PFMEAs reduced external PPM from PPM a month to PPM a month
  • Championed resolution of Customer Quality Concerns, and trained Production on investigation techniques
  • Worked with manufacturing to develop and implement pokayokes in the extrusion and finishing processes
  • Launch lead for Altima for door seals, and Maxima for parting seals
  • Lead efforts in acquisition of ISO/TS by facility
  • Aisin Manufacturing Illinois LLC, Marion IL

  • Downsized out of job due to business issues at customer
  • Lead efforts to resolve popping noise with powered back door.  Issue was % of the quality concerns
  • Revised and developed Standard Work Instructions, Control Plans, Toyota Inspection Standards TIS, and PFMEAs
  • Lead Efforts to resolve customer issues, and train Production on root cause reduced external PPM by %
  • Launch Responsibility for Sequoia Power Back Door & Sienna Power Slide Door Closer and Lock Assy
  • Haldex Hydraulics Corporation, Rockford IL

  • Downsized out of job due to business issues at customer
  • Lead Supplier in standardizing measurement techniques reduced supplier related PPM by %
  • Developed system of Audits on suppliers per corporate guidelines and TS criteria
  • Jernberg Industries, Incorporated, JII Machining Division, Chicago, IL

  • Left Jernberg Industries for fulltime study at Western Michigan University
  • Lead Effort to improve FPY, including performing Capability Analysis & SPC of machined parts, kaizen
  • Lead Efforts to setup and maintain database to keep track of nonconforming material reduced machining scrap by %
  • Internal Auditing to QS/QS standards


    Mechanical Engineer, Manufacturing Engineer, & Process Engineer, HVAC&R, automotive, aerospace

    Vantage Mobility International LLC, Phoenix AZ

  • Independent Contractor
  • Process Mapping, DFMEA, PFMEA, and cost justification for new equipment
  • Production Launch GEN Honda Redesign Floor Module, Exhaust Module, Slide Door Module, Seat Base Module,
  • Fuel/Vapor Lines Module

  • Lead efforts in developing systems that were compliant to TS
  • The Timken Company, Timken Aerospace Aftermarket Solutions, Mesa AZ

  • Downsized from Timken due to economy
  • Revised, rewrote, and created new Standard Operating Procedures SOP for operations in Foundry
  • Implemented Statistical Process Control SPC on for casting operations in Foundry reduced foundry scrap by %
  • Lean/S in Foundry Operations increased wax assembly process machine availability by %
  • Lead in the development of systems per AS ISO
  • Dana Corporation, Sterling, IL

  • Lead a production launch that encompassed five different series valued at US$. million in business for facility
  • Lead efforts within facility per transition from QS to TS .  Internal Auditing of Processes
  • Lead Six Sigma Black Belt projects in the areas of driveshaft painting and other processes US$K annual savings in Worker’s Compensation & US$K annual savings in Driveshaft Painting
  • Develop and design tooling, fixturing, and assembly processes for new product introductions in the facility, and managed the reconditioning, and calibration, of tooling/fixturing within facility
  • Lead several kaizen events in facility US$K annual savings in one event for driveshaft remanufacturing
  • Triatek Holdings LLC, Norcross GA

  • Days Contract Opportunity in Mechanical Design
  • Redesigned venturi air valve and optimized spring in valve to better fit theoretical calibration curve.  FPY increased from % to % in process
  • Developed Flowchart, PFMEA, Control Plan, and Work Instructions of Venturi Air Valve reduced assembly errors by % 
  • Dana Corporation
  • Lead production plant, total of people in Value Stream Mapping & establishing a Rapid Baseline among lines of Dana Production Systems DPS.  Information used to develop foundation, set priorities, and coordinate lean activity for fiscal year, and to mentor and train others in lean concepts and kaizen.   Total of Black Belt opportunities identified, kaizen opportunities identified.  Tools Utilized:  Pareto Analysis, Process Mapping/VSM, Financial Analysis/ROI, Kaizen, Time Study, Process Walk, Takt Time, COQ,  Takt Time, FPY
  • Mentored, trained, and coached ISO Coordinator, and Quality Manager in Lean concepts, kaizen & S techniques, and Six Sigma.  Quality Manager, and ISO Coordinator went on to be certified Six Sigma Green Belts through Dana Corporation.  Tools Utilized:  Pareto Analysis, Process Mapping, Kaizen Event, S, PDCA, COQ, Takt Time, Hypothesis Testing, SPC, OnePieceFlow, Time Study, Root Cause,  FMEA/EMEA, QFD/SIPOC, FPY,  Cell Layout, PDCA, Financial Analysis Training
  • Lead Six Sigma Black Belt Project, Mentored & Trained Team of people over course of months including outsourced paint supplier, Optimizing Driveshaft Painting Process. Savings US$K annual.  Tools Utilized:  Pareto Analysis, Process Mapping, Financial Analysis/ROI, Hypothesis Testing/ANOVA, Kanban, PDCA, SPC, Root Cause, Fishbone, WhyWhy, COQ, QFD/SIPOC, FPY, PFMEA
  • Lead Six Sigma Black Belt Project, Mentored & Trained Team of people over course of months, Worker’s Compensation Management Process. Savings US$K annual.  Tools Utilized:  Pareto Analysis, Process Mapping, SPC, Root Cause, COQ, PDCA, EMEA
  • Lead Kaizen Event, Mentored & Trained Team of people over one week, Driveshaft Remanufacturing, reduction of time from days to days to remanufacture driveshaft, true labor cost of remanufacturing driveshaft realized. Savings US$K annual. Tools Utilized:  Pareto Analysis, Process Mapping, SShadow Board, Time Study, Pokayoke, Takt Time, OnePieceFlow,  FPY, Cell Layout, Financial Analysis/Calculating ROI
  • Supplier Development, Lead team of people with setting up kanban for tube cutoff length through kaizen.  Savings US$K annual Tools Utilized:  Process Mapping, Kanban,  Milk Runs, SPC, takt time
  • Project Manager for a new line of driveshafts that encompassed localizing five different series in charge of tooling development, developing and maintaining project timeline, and assisting Purchasing Manager with sourcing of components.  US$. million in new business annually & and allowed closing of warehouse for receiving of overseas product reduction of people, savings of US$K annually.  Trained & mentored Production, Maintenance, Quality, and Sales people regarding new production equipment and driveshafts.  Tools Utilized:  MS Project, PERT/CPM, Pareto Analysis /, DFMEA, PFMEA, Cell Layout, ROI
  • Value Analysis & Value Engineering VA/VE experience with the redesign of a Spicer Axle used in golf carts designed % of the cost out of the product; improved fit, form, function, capitalized on Dana Corporation patent, met target price, simplified product design, reduced from U

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