Andhra Pradesh State Board

University of the Cumberlands

University of Houston

SRM University

Manufacturing Engineering Lead - New Programs

Greater Bloomington, Illinois Area

General Assembly R1 Program new model launch and MES integration lead (Jan 2022 – Now)
- Program milestone planning and tracking with a focus on statuses and input/output metrics using Atlassian (Jira, Confluence) and Smartsheets
- New program CAPEX budget and risk mitigation planning
- Developing strategies for product, equipment, and process validation builds (VP, TT, PP, SOP) to produce high quality products at high volume
- Planning and leading simultaneous engineering, virtual builds, and virtual commissioning activities
- Lead and train teams to execute DFA, PFMEA development, Line Balancing, and Headcount planning activities

R1T/S General Assembly Trim Shop ME Lead and GA MES Lead (Feb 2021 – Jan 2022)
- Led a group of 6 Sr. ME’s, ME’s and Contract IE’s in planning and launching 5 Assembly lines
- Manufacturing Feasibility – DFM, DFA, Cycle Line Layout and Headcount Planning
- Worked with shop leads, TPM’s in planning, and tracking to completion of VP, TT, PP builds and SOP readiness
- Developed weekly capacity plan for R1T/S 2022 GA Capacity Plan to achieve 2022 MPP
- Strategized weekly and monthly OEE targets to ramp-up using a bottoms-up approach
- Developed and accomplished strategies for successful GA ramp -> 10+ to 4 mins takt in 3 months
- Participated in Product Design and Change Management reviews - Evaluated and provided manufacturing impact on DFA, process sequence, cycle times (e-HPV), equipment & tooling
- Developed and monitored team KPI deliverable statuses, provided efficient methods and solutions to resolve technical and program issues without impacting project timing and CAPEX spend
- Managed $10 Million CAPEX projects in collaborating with tooling integrators for Automation Equipment, Lift Assists, Torque Tools etc.,
- Established and validated, fault and failure recovery methods for manual processes and automation equipment
- Factory System Integration: Developed Rivian MES system for GA and integrated it with shop PLC’s
            

    
    

    
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Rivian

Staff Manufacturing Engineer

R1 program (R1T, R1S) General Assembly Trim Shop Manufacturing Engineering Lead responsible for planning and launching 5 Trim lines (Trim 1/2/3, IP, Doors) and leading a group of 6 Manufacturing Engineers and 2 Contract IE’s.

Horizontal Responsibilities:
- Manufacturing Feasibility - Ergonomics, DFX (DFM and DFA); Cycle Line Layout Planning and Station Readiness; Line Balancing and Headcount planning
- Identify gaps (Process, Business) and developing efficient methods to improve team efficiency
- Develop structured, data-driven and quantitative problem-solving approach
- Collaborate with all departmental functions across the company to ensure successful delivery of projects
- Work with other GA leads, TPM’s in planning, tracking, and implementation of VP, TT, PP builds and SOP readiness

Vertical Responsibilities:
- Participated in cross-functional 3D CAD product and change reviews - Evaluated and provided manufacturing impact on DFA, process sequence, cycle times (e-HPV), equipment & tooling
-     Developed and monitored trim team KPI's and deliverable statuses, provided efficient methods and solutions to resolve technical and program issues without impacting project timings and managed CAPEX spend
- Collaborated with equipment, assist tool, and custom tool integrators and managing projects worth of 10 Million Dollars
- Ensure trim team is consistently following standards procedures and protocols
-       Plan new plant layout and carriers for Final Assembly in collaboration with Equipment team and LESCO (Ext. Integrator)
-      Established and validated, fault and failure recovery methods for manual processes and automation equipment
-      Factory System Integration: Developing Rivian MES system for GA and integrating it with shop PLC’s
            

    
    

    
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Senior Manufacturing Engineer - Lead

R1 program (R1T, R1S) General Assembly Trim Shop Manufacturing Engineering Lead responsible for planning and launching 5 Trim lines (Trim 1/2/3, IP, Doors) and leading a group of 3 Manufacturing Engineers and 2 Contract IE’s.

Horizontal Responsibilities in General Assembly for Trim, Chassis, & Final shops include:
- Manufacturing Feasibility - Ergonomics, DFX (DFM and DFA); Cycle Line Layout Planning and Station Readiness; Line Balancing and Headcount planning
- Identify gaps (Process, Business) and developing efficient methods to improve team efficiency
- Develop structured, data-driven and quantitative problem-solving approach
- Collaborate with all departmental functions across the company to ensure successful delivery of projects
- Work with other GA leads, TPM’s in planning, tracking, and implementation of VP, TT, PP builds and SOP readiness

Vertical Responsibilities in General Assembly for Trim shop include:
- Provide technical support to the team, necessary trainings to new hires and existing team members
- Develop monthly, weekly, and daily deliverables for the team based on program milestones
- Monitor trim team KPI's and deliverable statuses, providing efficient methods and solutions to resolve technical and program related issues without impacting project timings
- Collaborate with equipment, assist tool, and custom tool integrators and managing projects worth of 10 Million Dollars
- Ensure trim team is consistently following standards procedures and protocols
- CAPEX forecasting, capacity planning, and future factory planning
-       Participate in cross-functional 3D CAD product and packaging reviews - Evaluating process impact and providing feedback on DFM/DFA, process/cycle times (e-HPV), build sequence, and capturing equipment & tooling requirements
-       Plan new plant layout and carriers for Final Assembly in collaboration with Equipment team and LESCO (Ext. Integrator)
            

    
    

    
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Lead Manufacturing Engineer

G.A. Manufacturing Engineer responsible for launch of 7 assembly lines (Trim 1/2/3; IP, Doors; Final 1,2) and mentoring 3 Manufacturing/Process Engineers.

- Collaborate with DRE’s to develop and establish a design with high built-in quality (GD&T, locating strategy), and assembly feasibility that lends itself into high volume production
- Delegate tasks to Manufacturing Engineers, keeping a track of deliverables and accomplishments, provide technical support as needed
- Lead virtual build sessions for Trim & Final lines, by planning assembly sequence in ENOVIA assembly design module using 3D CAD data
- Participate in cross-functional 3D CAD product and packaging reviews - Evaluating process impact and providing feedback on DFM/DFA, process/cycle times (e-HPV), build sequence, and capturing equipment & tooling requirements
- Plan new plant layout and carriers for Final Assembly in collaboration with Equipment team and LESCO (Ext. Integrator)
- Design cycle line layouts, Perform line balancing, and Plan kitting, sequencing, and sub-assembly cells to generate optimum head counts (manpower), best line/station efficiency and operator ergonomics
- Collaborate with ext. equipment integrators: ESYS, HTI, Knight Global, & Atlas to develop complex/custom equipment (Manual & Automated Assist Arms, Glass Cells, Special Tools)
- Manufacturing lead for planning and developing business tools: PLM 3D Exp (ENOVIA, DELMIA), Rockwell MES
- Assist program in developing business work flows (Change Management, Attributes Alignment, Launch Management), and assembly documentation (PAD, Manifest, SOS, JES, etc.,) using APQP principles/best practices
- Make vs Buy: Develop competitive and structural cost analysis for Sub-Assemblies, Kitting, & Sequencing which include manpower, floor-space, and cost reports
- Develop work instructions (SOS & JES) in process development phase
- Develop PFMEAs and implement process controls
- Supported Battery shop in Module and Battery Pack mule builds
            

    
    

    
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Manufacturing Engineer

Led New Product Launch & Series Production of GLS, GLE, GLE Coupe, GLE Hybrid SUV's managed Door, Trim 4, & Trim 5 assembly lines in GA - Processed Seats, Windshield, Liftgate Glass, Center Console, Wiper System, Carpets, Running Board, Interior Trim parts etc.,

- Planned Build Sequence, Process Layouts, Special tools, Jigs & Fixtures, Ergonomics, Lean Assembly Methods, Safety, JIS & JIT deliveries
- Performed time studies and optimized station utilization by evaluating process times using MTM C-Codes and performed Line Balancing activities using Proplan
- New Product Launch BR167 - Led production team on the shop floor, verified planning and any build concerns during Null Series, Production Trials (PDCA), and SOP Launch
- Worked with production group leaders planned headcount, and analyzed team member Capacity & Capability
- Reviewed product design changes - ECN's, prepared change information sheet for implementing and communicating with Engineering and Production
- Responsible for creating AutoCAD Layouts, Process Flow Diagrams, Spaghetti Charts, Trackers, Process Change Requests, Broadcast Sheets, Rack & Limo designs
- Led cross-functional projects using new lean concepts (MPS) and continuously improved line utilization, downtime, ergonomics, product quality
- SQC - Used statistical tools to determine process capability and implementing all the VA/AA, PDR, and Q-Release quality requirements
- Created and updated production documentation using DPE - Standard Method & Procedures, Job Element Sheets, Tools & Parts Sheet
- Responsible for maintaining ISO 9001, TS 16949, 5S, DZ (Global Country Stds - DOT, SAE, CCC), DS (FMVSS) and supporting line Audits
- Coordinated with logistics to review PFEP thru SAP AM Supply and plan JIT & JIS deliveries from the supplier
- Prepared production cost analysis reports for in-house projects and sub-assemblies of BR167
- NLC AGV Projects: 167 Cart Modification, Buffer Reduction, Pick Light (Poke-Yoke), KSP AutoCAD Layout Design
            

    
    

    
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Mercedes-Benz U.S. International, Inc.

Series Planning Assembly Engineer

Capital Project Spare Parts Specialist - $9.8 Billion Green Field Project – Sasol Petrochemicals Ethane Cracker (Sasol-North America) Louisiana, USA - Contract thru Petroplan/TRS Staffing

- Strategic sourcing of all Mechanical (static, rotational), Electrical (HVAC, switches), Electromechanical (automation), and Instrumentation (transmitters, sensors) spares for Ethane cracker, LDPE, LLDPE, MES, and EO/EG units
- Coordinated with O&M and Suppliers, performed reliability analysis using equipment failure rate and part/product lifecycle test reports and planned 2 years MRO Spare Parts (SAP) inventory and planned warehouse facility layout
- Prepared and submitted quote requests (RFQ’s), nondisclosure agreements to suppliers and negotiated prices, storage (VMI), and logistics (3PL) terms with suppliers
- Managed project milestones, supervised timely submission of commissioning PO packages(OTD) from EPC’s (Technip, Fluor, Toyo) and Suppliers and submitting monthly status reports to stakeholder using project tracker
- Created/enhanced quality and accuracy of SPIR report reviewing equipment drawings, PID, and equipment data sheets
-  Reviewed PO's, BOM, material certifications, equipment & operational data sheets, PID, and life cycle test reports of all incoming parts/equipment for quality evaluation
-  Categorized previously ordered equipment or spares parts into Startup, Capital or 2 years spares  based on prices or costs in the SPIR report and SAP BOM
- Supported IT in creating Master Tag List, SAP Data Base - SAP MM, BOM, SKU creation using MDRM data and SPIR reports
            

    
    

    
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Sasol

Spare Parts Specialist - Capital Projects

SIOP, SAT reviews, Demand Planning & Forecasting, Kanban Sizing, Commodity Strategy, Vendor Analysis, Supplier Qualification, Supplier Performance Evaluation, Maximize Cash Flow, Rough Cut Capacity Planning

NPI Project Management, US, Germany, & Slovenia
- NPI Project Management: FKX9000 Triple Offset Valve, capital expenses & ROI on new machine purchase, process standardization for Phase 1 orders (3"- 32" size Lug, DFS, & DFL), MRP Tracking, Supplier Qualification
- Worked with production in planning new Jigs & Fixtures for Valve assembly
- NPI Phase 1 Program Management: Order tracking, gap analysis, worked with management and key stakeholders from various departments to continuously improve order processing process
-        Worked closely with Production team, performed manufacturing capacity analysis, weld and machining quality inspection, designed fixture for assembling valves >20" in short pattern, evaluated NDT reports, torque test and life cycle tests results - for Phase 1

Global Supply Chain Analyst, Woodlands, TX
- Global Supplier Performance: Collected and analyzed global sites data and created Supply Chain KPI’s and Supplier Score Cards focused on OTD (Time), Quality, and Costs (PPV) to drive continuous improvement in the supply base
- Assisted commodity managers by Creating Commodity Strategies and commodity cost/price analysis reports and recommended VAVE projects, Suppler Consolidation projects, LCC & LTA contracts and reduced finished product costs
- BI tool implementation: Coordinated with BLM's across multiple locations to align SKU’s/Part number with SIOP forecast codes, to generate accurate forecasts
- Utilized Atlas & Prism BI tools to forecast and analyze inventories from 26 sites across the world using 11 ERP systems
- Reviewed Forecast Vs Actual values of Shipment, Inventory, and COGS at sites and made MRP & SIOP reports for review
            

    
    

    
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Crane Co.

Global Supply Chain Intern

Royal Technocrats

Intern

Course Work: Managing Productivity and Quality.

-  Trained undergraduate students on Lean Principles, Kaizen, Kanban, Ishikawa - 5 Why analysis,  Just-in-Time, Value Stream Mapping, Value Engineering (7 wastes), Six Sigma, and 5S concepts
-  Assisted 24 undergraduate students teams on 5S (Visual Management) and Six Sigma DMAIC (Control Charts, Pareto 80-20, 5 Whys, Cause and Effect Diagram) projects
-  Evaluated and documented results of students based on their performance

Instructional Assistant - Lean & Quality

Contract thru Sarvan Shipping Ltd., and SESA Goa.

Participated in cross-functional team reviews to improve productivity (VSM, SQDC).

- Responsible for creating & developing PFD’s, PFMEA, Control Plans (Poke Yoke), SOP’s
- Worked with Supplier on improving incoming part quality, conducted supplier site audits, VAVE analysis, and training
- Performed process capability studies using SPC techniques (torque evaluation) and calculated process efficiencies (Cp, Cpk) to reduce scrap
- Conducted Root Cause Analysis (5 WHY’s) on non-conformities and implemented corrective and preventive action plans
- Led and participated in Capital & Kaizen projects saving INR 16.5M - reduced wastes/non-value steps and improved process quality by implementing Six Sigma DMAIC methodology, Lean Tools, and A3 problem-solving
- Handled in-house 5S and Safety workshops, conducted Ergonomics Analysis, 5S, Safety, and Process audits
- Evaluated and re-designed shop floor layout of production and packaging areas by 5S, U-Shaped Lean Layout, and Lean Assembly process - Improved site productivity & safety
- Improved utilization of Volvo Dumper assembly line by 23.5% by conducting Time Studies, Line Balancing and Lean processes
- Reviewed drawings, material availability, process routing, & shop support before releasing a Work Order
- Supply Chain: Performed statistical analysis to forecast the demand of parts, and implemented JIT-Kanban and maintained Safety Stock levels
- Reduced operations time by developing warehouse layout using 5S, Cartesian Coordinates, and RFID system
            

    
    

    
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Vedanta Resources Limited

Senior Mechanical Engineer

Gained experience in Lean Manufacturing, 5S, Theory of Constraints, SPC Tools, Quality Inspection/checks, PMTS, MODAPTS, JIT - Kanban Flow, Visual Control, Safety, 8D Methodology

- Assisted in creation of Assembly Work Instructions, PFD’s, Process Control Plans, Check Sheets, and PFMEA
- Performed Time & Motion Studies, and Takt time analysis for 13A body assembly line of  Fiesta (2) and Figo (1) models to improve flow/throughput using improved Kanban Flow to line and Line Balancing
- Executed & documented pilot runs (PDCA), Capacity planning, JIT Kanban design, Line balancing for various line speeds
- Achieved the project objective by decreasing takt time by 20%, consequently increasing productivity by 25%

Design Phase
- Re-designed the transmission system using AutoCAD & SolidWorks (maintained ANSI standards)
- Simulated proposed conveyor gear train designs using ANSYS, obtained stress values, factor of safety, and maximum attainable speed - varying loads
            

    
    

    
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Himamsu Maremalla

Himamsu Maremalla