Rajesh Gundimeda

Key Accomplishments

• New Technology: Driven new technologies to customers like organo and PA activities
• Business Strategy: Winning average of 1 new business per year to EK location
• VA/VE - $ 200,000.00: Executed Volvo VA/VE gray to black color resin implementation
• Revenue increases $ 1.4 M: Overall revenue increased in 2022 due to material price increase negotiations with customers
• Programs Launched: Successfully won and launched Navistar CBE 1 engine programs to EKCA ($800K), EKSA ($500K)
• Innovative Project: Fender prototype project awarded by the Daimler Truck North America ($800K)

Responsibilities

• Business Strategy: Reviewed the business strategy within EK and customers, regular contact and visits with customer buyer and technical team to discuss new business
• VA/VE: Provided VA/VE ideas to customers and BUs to save the costs, scarp and weight of the products
• RFQ’s and PO’s: Defined pricing, prepared cost models, packaging’s costs and RFQ’s to customers
• Program Management: Organized, provided leadership in directing a cross functional team to ensure overall co-ordination and synchronization of program activities from design concept to launch with kick off /production launch meetings
• Executed programs with proper planning, resourcing and scheduling
• Documentation: Prepared RePA’s, TFC’s, Birth certificates and approved GSPT’s accordingly
• Communication: Maintained interface for project documents to the customer’s departments during the project period in accordance with agreed communication matrix
• APQP and Open Issues: Assembled and lead APQP team to ensure launch is completed in scope, maintaining and assuring a master program management system and APQP requirements
• Generated and maintained the program open issues list and program timelines
• Change Management: Initiated the change management in case of change requests provided by customers throughout the entire projects as well in case of EK internal changes requests until transfer of the project leadership

Key Accomplishments

• Saved $ 868,908: Executed all the beta prototypes projects with scope and saved average of 39.4%
• Saved $ 165,965: Developed, implemented new automation process, and new process to check the products
• Programs Launched: Successfully launched GM CSS Pickup tubes ($1.2 M), GM Oil Pans ($1.7 M), Gen V Oil Separator ($ 650 K), and DDC Resonator ($ 450K), DDC 13 Oil Pan ($.1.3 M), PACCAR- DAF Oil Pans ($1.1M), Mack 11L ($950K), Mack Wire Harness Frames ($215 K) assembly lines with scope

Responsibilities

• Design: Reviewed product designs from prototypes to production with internal product engineers, customers, suppliers and internal cross functional team and kicked off tools and assembly lines for the production
• Program Management: Provided technical and program leadership in directing a cross functional team to ensure overall co-ordination and synchronization of program activities from design concept to launch
• Executed programs with proper planning, resourcing and scheduling
• Purchasing and Installation: Purchased advance equipments and integrated with the systems increased quality
• RFQ’s and PO’s: Prepared RFQ’s and reviewed proposals of outside vendors and issuing PO’s for prototypes, new or modernization of existing production and processing equipment
• Budget and Costing: Prepared budgets and controlled expenditures in line with budget allocation
• Determined and approved product specifications or functional requirements ensuring they meet customer needs
• Managed tooling suppliers including costing, tool designs, builds trials and production sign off
• APQP and Open Issues: Assembled and lead APQP team to ensure launch is completed in scope, maintaining and assuring a master program management system and APQP requirements
• Generated and maintained the program open issues list and program timelines
• Validation and ECR: Developed specifications and test procedures to validate product and evaluate test results
• Coordinated and ensured the implementation of customer changes of product after launch
• Packaging and Shipping: Participated in expendable and returnable package proposal kick off with customer and facilitated shipping products for prototypes and production launch
• Tool Trials, PTR’s and Run at Rate: Facilitated tool trails and prepared documentation for run at rate and PTR’s
• Quality Audits: Prepared documentations to retain ISO/TS 16949/ISO 14001 certification and customer audits
• Assistance: Provided programs and technical assistance to account managers and customers

Key Accomplishments

• Saved $181,000: Developed layouts, automation cells with new design and process in each assembly line
• Lean Manufacturing: Reduced set up times by implementing lean methods, increased quality and production
• Programs Launched: Successfully launched GM Powertrain Assembly Line Gen V ($3.6M), FAM 0 MOD 3 & 4 ($2.5M) and Chrysler retooling ($1.3M) with scope and saved overall 31.5% for all the programs launched

Responsibilities

• Design and Automation: Developed and designed reviewing equipment’s, assembly lines, automation cells and process
• Generated plant layouts and created BOMs
• Provided objectives to the design team, achieved productivity and budget targets
• Studied work cells and line balance to determine bottle necks and potential design improvements to increase production rates
• Project Management: Identified resources and requirements, tracked project progression using project management tools
• Successfully achieved project deliveries by planning and scheduling projects, controlling and evaluating the activities and operations with the respective departments
• Validation and Technical Reports: Validated equipments, tooling and fixtures, prepared protocol and final reports for equipment set up and run off
• Continuous Improvement: Conducted research and investigated in the design, process, feasibility and time studies, cost analysis and applied continuous improvement techniques to improve productivity, quality improvements and cost reduction
• Supported production in all aspects of operations and improvement opportunities
• PFMEA and Control Plan: Developed, implemented and documented risk analysis, PFMEA, DFMEA, Control Plans and corrective actions in facilities
• Purchasing and Installation: Purchased advance equipments and integrated with the systems increased quality
• Project Coordination: Provided project coordination and technical assistance to various multi discipline teams, closing open issues, customers, suppliers and vendors to ensure successful completion of projects
• Documentation: Developed, implemented and maintained documentation for PFMEA, DFMEA, PPAP, Operator Instructions, Rework, change - over procedure and instructions, time studies, process capability studies, trail runs, customer runoffs, manufacturing and production engineering open issues and new program monitoring requirements
• SOP, CEA, RFQ, and PO: Prepared SOP's and CEA's to get approve for the funds regarding the purchasing of new advanced equipments
• Preparing RFQ’s and issuing PO’s for multiple projects

Key Accomplishments

• Saved $45,000.00 annually: Implemented lean manufacturing regarding process which saved the scrap with new automation equipment’s, delivering an 8-month ROI
• Saved $21,000.00 annually: Reduced scrap by inbuilt customized equipment and reused part for production, delivering a 6- month ROI
• SMED and Kaizen: Reduced setup time up to 79% by implementing SMED techniques, implemented Andon Systems, standardized quality control tools (e-DART) and operating instructions which increased the quality and production
• Programs Launched: Successfully launched Toyota D10 ($ 850 K) and D11A ($1.5M) manufacturing and assembly program

Responsibilities

• Automation: Automation of injection molding machines with robots and box changers which increased in the productivity
• Successfully completed regrind process automation project which saves $45,000 per year to the company
• Developed new automation process in the machine to increase the efficiency of production
• Design and Process: Designing and fabrication of the stripping machine process with more ergonomically which saves $21,000 per year profitable to the company
• Design of E.O.A.T‘s for automation
• Design analysis for future machine and process production
• Design and development of plant layout and required automation components
• Project Management: Generated, monitored and controlled the projects with proper SCOPE
• Purchasing and Installation: Purchased new advanced technology equipments for injection molding and installed that succeeded to produce high productivity and quality
• Continuous Improvement: Analyzed and implemented continuous process improvements in the plant
• Work Instructions: Generated standardize work instructions for the equipments and mould tools for proper operation and preventative maintenance
• FMEA and Flow Charts: Developed FMEA for the process and equipments, flow charts and graphs for machine utilization and work flow process
• Preventative Maintenance: Prepared and maintained PM activities for the equipments
• Time Standards: Time studies conducted for machine down time, work force, material usage and FY process survey
• Training: Training the tool room and maintenance teams regarding machine operation and software tools
• Trouble Shooting: Assistance and support to technicians and outside suppliers for trouble shooting and installation of the machines in the plant

Key Accomplishments

• 5S: Implemented 5S throughout the manufacturing area

Responsibilities

• Design: Generated and updated plant layouts and process to improve efficiency and production
• Generated and created BOMs
• Analysis: Conducted research and time studies on process and production analysis
• Cost Reduction: Analyzed and implemented action plans effectively to maximize overall equipment efficiency of production machines
• Initiated cost reduction with efficient production planning and machine loading
• Production Planning: Maintained perfect production planning, work schedule and work process
• Supervision: Supervised and managed the work process and workers in control and proper manner
• Production Schedule: Distribution of work load to operators in order to achieve daily production target
• Project Management: Generated and monitored the projects of automation and design fabrication
• Preventative Maintenance: Scheduled tasks and activities for equipments PM
• Operating Instructions: Generated, developed and implemented Operating Instructions
• Training: Arranged certain training programs to enhance productivity using improvement techniques in company