Project

8 DMAIC
160,000 Sq ft
11% efficiency
26% Pick path
man-power/ cost reduction

CI cards
L& T Tenure
Sanford, CAT
NPI Projects
Tier 1 Companies
Apple
Novartis
Microsoft
Commscope
Tech Mahindra
Scadea Software solutions
Roles
Solutions Engineer
Project Manger
Consulting Project Management
CPI
Tier 2 Companies
Persona Project Manager
Keywords
Deliverables
Resources
Agile
Agreements
Audits
Baselines
Benchmarking
Bid Documents
constraints
Daily stand up meeting
Activities
Scope
Development lifecycle
Enhance
Esclate
Executing
Exploit
Facilitation
Intiating
Inspection
Interviews
Observations
Stakeholder
System
Transfer
Validate
Variable
Variance
Verified
Virtual
Voting
Assumption
Defect
Duration
Portfolio
Phase
Requirements
Resources
Mitigation
Dashboards
Effectutae
Operations
Long-term
Business needs
Soft Skills
Active listening
Brainstorming
Conflict management
Decision making
Emotional intelligence
Problem solving
Project Coordinator
Project reporting
Servant leadership
Project Expediator
Optimizer
Solutions-Oriented
Detail Oriented
Training
Comprehending
Analytical Skills
Challenges
Detail Oriented
Technical and business problems
Fuel
Coaching
Removing impediments
Deployement
Priority
Determine
Budget
Timeline
Customer
Progress
people management
Outsourced
Transition
Monitor
Provision
Portfolio
Reporting
Appropiate
Steering Committee
Adherence
Colloborate
Effective
Complex
Adeptly
Emotional intelligence
Overseeing
Inception to delivery
Ensuring alignment with business objectives, timelines, and budgets
Embark
Ensuring
Comprehensive
Resource allocation stratergies
risk mitigation plans
Proactive and timely manner
Motivated
meticulous organization
Engages
Expertise
Prevents
Leverages
Workstreams
Business Networking.
Compliance Management.
Compliance Risk.
Curiosity.
Flexibility.
Leadership.
Operational Risk.
Regulatory Reporting.
Risk Control.
Risk Management.
Senior Management.
Technical Keywords
Activity list
Affinity diagrams
Alternative analysis
Cause and effect diagrams
Bar Chart
Benefit cost ratio
Beta distribution
Bottom-up estimating
Budget estimate
Burn Charts
Business case
Checklist
Checksheets
Claims administration
Procurments
Collect requirements
Context diagrams
Continuous improvement
Control charts
Cost aggregation
Work break down
Critical path method
Cycle time
Data analysis
Data gathering
Data representation
David McClelland's theory of needs
Decompostion
Delphi technique
Design for X
Project Charter
Project management plan
Earned value
Earned value analysis
Fast-tracking
Flowcharts
Focus groups
Herzberg's theory
Histogram
Identify risk
Identify stakeholders
Manufacturing Engineering
AutoCAD
Supply Chain Management
Kaizen
5S
Computer-Aided Design (CAD)
Data Analytics
Technical Keywords
Issue log
Just in time
Kanban
leads and lags
Lean
Lessons learned register
Make or Buy
Maslow's hireracy of needs
Milestone charts
Mind mapping
Nominal group technique
Opportunity cost
Parametric estimating
Plan-Do-Check_Act
Precedence Diagramming method
Product analysis
Product backlog
Product lifecycle
Progressive eloboration
Quality Metrics
Quality reports
Questionnaries and surveys
Requirements documentation
Reseve analysis
Resource breakdown structure
Resource leveling
Risk register
Rolling wave planning
Root cause analysis
Scatter diagrams
Sensitivity analysis
Sequence activities
Six-sigma
Source selction analysis
Standard deviation
Startegies for opportunities
SWOT analysis
Trend analysis
T-shirt sizing
Tuckman's ladder
Muda, Muri and Muda
Process re-engineering
Process efficency
VA/NVA
Prototypes
What-if Scenarios
Acceptance critiera
Change request
Corrective action
Fast-tracking
Gantt Chart
Schedule compression
Assign and oversee the daily tasks of technical personnel while ensuring all sub
Detail-oriented- Eye to details in terms of documentation, gathering client requi
Orchestrates and oversees a broad range of project metrics on large, complex p
reviewing work of peers for quality
assists in developing Statement of Work (SOW), Work Breakdown Structures (W
Ensures use of baselining, resource load balancing, and application of work effo
Establishes clear expectations and accountabilities (e.g., reconfirm scope, Respo
expectations and accountabilities (e.g., reconfirm scope, Responsible-Accountab
Proactively engages broad set of internal and external stakeholders
Proactively ensures adherence to key performance indicators (KPIs) and provide
anticipates changes and proactively addresses by probing to ensure change can
Manages finances for projects with large scopes and budgets by balancing fundi
Drives timely project closure by ensuring completion of project sign off tasks
Drives incremental process improvement by reflecting on and broadly sharing le
Reporting of technical complaints / adverse events / special case scenarios
Collaborates with leaders to put into action Gemba walk process (Running for D
Provides lean status reports for both internal and external communications inclu
orking knowledge of basic and advanced tools such as Continuous Improvement
Kaizen; etc. Problem Solving ,5S; Visual Mismanagement; Value Stream Mapping
Collaborate with cross-functional teams, including designers, developers, QA en
Drives and owns the overall delivery of the cross-functional project (time, cost, q
Ensures financial stewardship at a project level by demonstrating an intimate un
drive the Con Mod process/negotiations and team execution to timelines.
Drives Risk Identification and Issue Resolution at project level (RBQM/RESOLVE)
Ensures project team compliance with organization policies, SOPs, ICH- GCP, reg
Develop and optimize assembly processes and equipment concepts from the off
Design assembly processes using planning methods for workflow optimization
• Participate in industrialization projects during planning and execution phases
• Create specifications for assembly systems
• Determine key figures for value-add calculations
• Track and achieve agreed cost and deadline targets
• Participate in interdisciplinary and international project teams
• Manage and support sub-projects for the industrialization of axle system assem
• Coordinate project-specific work packages with customers and suppliers
• Support and oversee machine suppliers throughout the entire project period
• Monitor, control, and finalize acceptance of assembly systems in the factory
• Ensure process acceptance by the customer
• Organize training and ensure knowledge transfer to employees in the product
• Argue and negotiate work results and concepts with customers and managem
Regularly review customer needs and/or requests to plan/optimize activities.
Interact with managers from various departments, along with engineers, custom
Manage project-related costs based on the established objectives;
Collaborate closely with the dispatcher and the service supervisor and plan labo
Document and complete reports intended for internal managers (project status,
Read and drive improvement projects specific to aligned account to create value
Should be well versed in FMEA / 7 QC Tools / Auditing procedures
Develop and implement process improvements to increase efficiency and produ
Analyze and evaluate existing processes and show areas for improvement.
Monitor and measure the effectiveness of process improvements.
Provide training and support to employees on process improvement methodolog
Collaborate with cross-functional teams to ensure successful implementation of
Develop and maintain process documentation and standard operating procedur
Function as a change agent to drive continuous improvement culture across the
Proven experience in implementing lean production techniques and improving p
Strong proficiency in production line process layout, workshop layout planning,
Experience in introducing and optimizing machine tools, fixtures, and production
Ability to analyze data, identify improvement opportunities, and implement effe
Proficiency in one specific area of Industrial Engineering (e.g., process optimizat
Excellent communication skills and the ability to collaborate effectively with cro
Coordinate and oversee various project elements, ensuring all aspects are align
Collaborate closely with cross-functional teams, including marketing, developme
Participate in planning and strategy meetings, offering insights and suggestions
Ensure all project activities adhere to organizational standards and best practice
Utilize project management tools (such as Asana, Trello, or Microsoft Project) to
Stay updated with the latest trends and methodologies in project management
Gather and incorporate feedback from team members and stakeholders, ensurin
Manage multiple projects simultaneously, prioritizing tasks and maintaining a hi
Handle administrative and PMO responsibilities, including preparing project docu
Process Design and Optimization: Design, develop, and optimize manufacturing
Continuous Improvement: Drive projects aimed at reducing production costs an
Quality Assurance: Establish and maintain stringent quality protocols to ensure
Team Leadership: Manage a team of engineers and technicians, fostering a cult
Training and Development: Assess team skills, identify gaps, and implement dev
Vendor and Supplier Management: Work closely with vendors and suppliers to e
Cross-Functional Collaboration: Collaborate with R&D, supply chain, sales, and m
Technical Strategy: Develop and articulate a clear technical strategy for manufa

To plan, execute, control and ensure closure of projects, while managing people
the project roadmap and manage entire project lifecycle from strategy planning
team members to engage with the customer. Ensure completion of Project Satis
concept to delivery by managing the project and governing the overall budget.
perspective. Ensure compliance to internal tools. Sensitize the team to go beyon
basis. Determine methodology and processes for quality planning (in concurren
processes, face audits and project process monitoring. Review project profitabili
customer. Ensure steering committee meetings and other regular meetings with
and other tools to ensure solutions are easy to manage and repeatable. Create
motivate, coach and develop people in the team to build functional skills and de
complex scenarios effectively like business risks, multiple vendor issues, code re
technical and other guidance as required to the team and assess the performan
Manage and oversee IT and Non-IT projects from initiation to completion, ensuri
Collaborate with CFOs and architects to understand project requirements, objec
Develop and maintain project plans, timelines, and budgets in alignment with or
Utilize Agile and Scrum methodologies to facilitate project execution, including s
Coordinate with stakeholders to prioritize tasks, resolve conflicts, and mitigate r
Monitor project progress, identify potential issues, and implement corrective act
Communicate project status, milestones, and key deliverables to stakeholders a
Foster a culture of continuous improvement by promoting Agile best practices a
Mentor and coach team members on Agile principles and practices to enhance p
Develop and own detailed project plans, including milestones, timelines, and res
Build and manage performance dashboards to track project metrics and KPIs.
Partner with the Sr Mgr, Tech Ops and business leaders on Technology’s Annual
Manage a calendar of key activities throughout the year and assist administrativ
Identify areas for process improvement and design and implement solutions.
Ensure key meetings are well-managed and successful, e.g., quarterly business
Coordinate with global teams, adapting to different time zones as necessary.
Project Leadership for a few key programs that are impactful across the technol
Act as a primary point-of-contact for project stakeholders.
Work with Technology managers and the Procurement team to enter and manag
1. Solved 150+ field hits by applying root cause analysis and following DMAIC methodology. (total warranty= $90,000+)
2. Ramped up the production from 5 axles/shift to 10 axles/shift: time studies, re-sequencing operations, process changes, acqui
3. Initiated and led continuous improvement projects to increase the efficiency of assembly & boxing processes by 22%.
4. Documented & solved 200+ assembly, boxing, & packaging issues on certified build in quality, velocity, and safety metrics.
5. Re-designed warehouse, order pick path & rack layout to reduce the average travel distance by 26% for order pickers.
6. Six sigma project 1: Cutting down the rejection rate in the die casting process of C346 pinion housing which resulted in signific
7. Created 2000+ operator-friendly, and engaging visual instructions.
g case studies)

nd in the office areas.

overnance standards.
xecution.
Rakesh Gajula 832 875 0827 | eshula3@[Link]
Professional Summary: Manufacturing Process Engineer with 4+ years of experience in designing production processes, executing operati
Highlights:
1. Solved 150+ field hits by applying root cause analysis and following DMAIC methodology. (total warranty= $90,000+)
2. Ramped up the production from 5 axles/shift to 10 axles/shift: time studies, re-sequencing operations, process changes, acquired adeq
3. Initiated and led continuous improvement projects to increase the efficiency of assembly & boxing processes by 22%.
4. Documented & solved 200+ assembly, boxing, & packaging issues on certified build in quality, velocity, and safety metrics.
5. Re-designed warehouse, order pick path & rack layout to reduce the average travel distance by 26% for order pickers.
6. Six sigma project 1: Cutting down the rejection rate in the die casting process of C346 pinion housing which resulted in significant savin
7. Created 2000+ operator-friendly, and engaging visual instructions.
Skills:
Manufacturing
Ergonomics
Quality
Design and Data
Computer Integrated Manufacturing

Experience:
Þ Caterpillar Inc.
1. Continuous Partial Improvement projects: Define problem statement from post-delivery customer feedback, containment action, iden
2. Gemba walk and production issues: Identify process improvement opportunities by observing, learning processes, investigation, critica
3. Field assembly improvement projects: Interface with multiple product groups to improve manufacturing efficiency by identifying cost
4. Manufacturing readiness projects: Organized and implemented 5 NPI projects; audits and correct documenting discrepancies, layout c
5. Continuous Improvement cards: Solve on an average of 20 cards/month originated by all stakeholders involved in boxing, assembly, p
6. Engineering Changes: Track and implement monthly Engineering change orders(ECO’s); update process changes, BOM (Bill of Material
7. Procuring tools, lifting devices and machinery: Conceptualize lifting device, virtually validate using CREO, fabricate and document Job s
8. Audits and Analysis: BOM & standard work audits, documentation grief reports, & monthly KPI’s metric reports.

Þ Integra Technologies. Industrial Engineer Wilmington, DE. Jul 2017 - Dec 2017

1. Captured the entire warehouse using a FARO M70 laser scanner. Conducted time-studies, VA/NVA analysis, ABC analysis, layout chang
Þ REF Technologies. Manufacturing Engineer Hyderabad, India. May 2014 - Jul 2015

1. Provided engineering support for the entire product life cycle; requirements gathering & conceptualize, cost-estimation, create BOM,

2. Conducted monthly kaizen, 5S, maintenance review meeting for the closure of red tags. Developed maintenance plans.

Education:

1. Master of Science in Industrial Engineering University of Houston

2. Bachelor of Technology in Mechanical Engineering JNTU, Hyderabad

Certification:

1. Six Sigma Green Belt – International six sigma institute.

2. Digital Manufacturing and Design (Industry 4.0) – University at Buffalo & The State University of New York.

3. Rigging and Material Handling – Osha The education center and the American Safety Council Inc

Rakesh Gajula 832 875 0827 | eshula3@[Link]

Professional Summary: Manufacturing Process Engineer with 4+ years of experience in process improvement, design, develop & impleme
Highlights:
1. Solved 150+ field assembly defects by applying root cause analysis & following DMAIC methodology. (total warranty= $90,000+)
2. Initiated and demonstrated ownership in continuous improvement project; increased operational process efficiency by 120%.
3. Solved 300+ Continuous Improvement cards on assembly, boxing, & packaging issues in quality, velocity, and safety metrics.
4. Re-designed warehouse, order pick path & rack layout to reduce the average travel distance by 26% for order pickers.
5. Six sigma project 1: Cut down the rejection rate in the die casting process of C346 pinion housing resulting in significant savings of
6. Project 2: Reduced the cycle time of logged IT service tickets from 18.52 to 15.3 using DMAIC methodology.
Skills:
 1. Lean Manufacturing: DMAIC, poka-yoke, 5S, Line balancing, procurement, Design workflows(work measurement & sequencing ope
2. Computer Integrated Manufacturing: CAPP+ ( Documentation tool), MES (PLM tool), MCS (MRP tool), HVC, EPIX & Teamcenter vism
3. Quality: PFMEA, Statistical Process Control, Gage R&R studies, 8D, cause validations, create quality gates, Fishbone, A3, PDCA.
4. Design and Data: Minitab, JMP, Tableau, MS Office, MS Access, Auto CAD, Creo parametric, MS Visio, SQL (basic queries).
5. Ergonomics and safety: REBA, RULA, &Team center JACK, Job safety analyses, work-station design.
Experience:
Þ Caterpillar Inc.
1. Continuous Partial Improvement projects: Lead process changes, define & the diagnose problem, apply root cause analysis, provid
2. Gemba walk and production issues: Identify process improvement opportunities through data analysis, process flow analysis, and
3. Field assembly cost reduction projects: Interface with multiple product groups to improve manufacturing efficiency; project ideati
4. Manufacturing readiness projects: Provided technical leadership, & strategically implemented 5 NPI projects; create & document M
5. Continuous Improvement cards: Solve ~20 cards/month originated by stakeholders in boxing, assembly, packaging, supply chain,
6. Engineering Changes: Track and implement monthly Engineering change orders(ECO’s), update BOM (Bill of Materials), torquing a
7. Procuring machinery and material handling equipment: Procure, purchase order, install machinery, test run in operating condition
8. Audits and Analysis: Create monthly report on engineering deliverables; Quality, Velocity, Cost, and Safety KPI’s. Collect, track & an
Þ Integra Technologies. Industrial Engineer Wilmington, DE. Jul 2017 - Dec 2017
1. Scanned the entire warehouse using a FARO M70 laser scanner. Conducted time-studies, VA/NVA analysis, value stream mapping, Par
Þ REF Technologies. Manufacturing Engineer Hyderabad, India. May 2014 - Jul 2015
1. Provided technical engineering support for the entire product life cycle; requirements gathering & conceptualize, time and cost estima
Education:

1. Master of Science in Industrial Engineering University of Houston

2. Bachelor of Technology in Mechanical Engineering JNTU, Hyderabad

Certification:
1. Six Sigma Green Belt – International six sigma institute.
2. Digital Manufacturing and Design (Industry 4.0) – University at Buffalo & The State University of New York.
3. Rigging and Material Handling – Osha The education center and the American Safety Council Inc

Rakesh Gajula
 Þ Summary: Manufacturing Process Engineer with 4+ years of experience in designing, managing, and executing manufacturing proc
Þ Highlights:
· Solved 150+ field assembly issues by applying root cause analysis & adhering to DMAIC methodology.(total warranty= $45,000+)
· Ramped up production from 5 axles to 8 axles per shift; time studies, line balancing, setup time reductions, modifying production
· Demonstrated ownership in increasing operational process efficiency from 61% to 83%; improved material presentation & materia
Þ Skills:
· Lean Manufacturing: DMAIC, poka-yoke, 5S, torque tooling, procurement, design workflows, BOM construction, sequencing opera
· Computer Integrated Manufacturing: CAPP+ (Documentation tool), MES (PLM tool), MCS (MRP tool), HVC, EPIX & Teamcenter vism
· Quality: PFMEA, Statistical Process Control, Cause-Effect, VA/NVA analysis, create quality gates, Fishbone, CAPA & PDCA.
· Ergonomics & safety: REBA, RULA, & Team center JACK, Job safety analyses, work-station design, & visual management.
Þ Experience:
® Caterpillar Inc.
· Launched 12 NPI’s (New Product Introductions); verify Design for Manufacturability (DFM), define process flows & assembly proce
· Solved 150+ field assembly issues; diagnosing customer feedback, defining the problem, root-cause analysis, determining solution
· Supported 30+ manpower and cost reduction projects resulted in $44K savings; creating project plans, developing processes, and
· Conduct Gemba walks to identify, investigate, and resolve safety and ergonomic issues. Designed workstation ergonomics, conduc
· Implement monthly Engineering change order(ECO’s) by updating process documentation, & training operators with changes.
· Design workspace layouts, & estimate space requirements and modify existing production layouts using Auto CAD.
· Procurement; capital and expense justification, managed external equipment integrators from design conceptualization through b
· Track and manage key KPI’s in quality, safety, velocity, and cost areas. Established new metrics by developing data collection tools
· Created 1000+ engaging standard work instructions and interactive visual instructions with safety and ergonomic information.
· Conducted time studies, re-designed operation sequence, process flow to maintain standardization across product groups.
® Integra Technologies.
· Role: Re-design order pick-path, rack layout arrangement, and warehouse layout.
· Responsibilities: Analyzing existing operations, value stream mapping, time-studies, Pareto analysis, implement process changes, i
® REF Technologies.
· Role: To oversee processes that convert raw materials to finished products. Troubleshoot daily production issues.
· Responsibilities: Product ideation with the customer, cost estimate, production time estimates, production line configuration, crea
Þ Education:

· Master of Science in Industrial Engineering University of Houston

· Bachelor of Technology in Mechanical Engineering JNTU, Hyderabad

Þ Certification:
· Six Sigma Green Belt – International six sigma institute.
· Rigging and Material Handling – Osha The education center and the American Safety Council Inc.
ovement projects. Proficient in data analysis, adept in-process observation, excellent mechanical aptitude, & passion for improvement.

DMAIC, poka-yoke, 5S, Line balancing, procurement, Design workflows, production layout, Time studies, tool commissioning, root cause an
REBA, RULA, &Team center JACK.
PFMEA, SPC tools, Gage R&R studies, cause validations, create quality gates, fishbone.
Minitab, JMP, Tableau, MS Office, MS Access,
CAPP+ ( Documentation tool), MES (PLM tool), MCS (MRP tool), HVC, EPIX & Teamcenter vismockup (design, print and model applications)
 Aug 2015 – May 2017

engineering projects, and track record in solving defect issues & continuous improvement projects. Proficient at data analysis, adept in process observa
hending new systems & processes. Expertise in lean manufacturing, production layouts, ergonomics, material handling & workplace safety improvemen

ective actions.
Manufacturing EngineerJan2018 – Present Decatur, IL.
 Sep 2010
– May 2014

strong mechanical aptitude & passion for improvement.

 Manufacturing EngineerJan2018 – Present Decatur, IL.

Aug 2015
– May 2017
Sep 2010
– May 2014

832-875-0827 | eshula3@[Link]
project management, creating standard work instructions, implementing engineering changes & process changes, time studies & line balancing.

Manufacturing Engineer Decatur, IL. Jan 2018 – Present

Industrial Engineer Wilmington, DE. Jul 2017 – Dec 2017

Manufacturing Engineer Jul 2017 – Dec 2017

Aug 2015
– May 2017
Sep 2010
– May 2014
time studies & line balancing.