Manufacturing and Quality Engineering

Injection Molding Optimization

Investigated the influence of different injection molding strategies on fiber orientation and mechanical performance of part made of KetaSpire KT-820 GF30.
Identifies the best injection molding strategy by performing material calibration and coupled FEA (with manufacturing data).

Designed an inexpensive and standalone computer vision system using a Raspberry Pi and Pi Cam to detect non-conforming parts according to specifications on the production line of Blue Ridge Thermoforming.
The system performed quality data collection, sent images of all parts to all connected computers, sorted images according to the product quality, analyzed the quality data to calculate the process yield, and built a database.
The system produced effective and intelligible data visualizations by data analysis.
Analyzed data to provide meaningful conclusions and make informed decisions to improve quality.
Achieved 98% system-level quality inspection accuracy making the measurement system acceptable.

Designed an assembly plant layout model on Siemens Tecnomatix Plant Simulation to meet the production demand of three types of automotive transmissions.
Minimized capital equipment investment and reduced operational cost by capacity planning and optimizing equipment selection to meet the production needs.
Analyzed downtime data to identify processes causing downtime and improved equipment and resource utilization by workflow optimization.
Tracked Key Performance Indicators (KPIs) and improved cycle time, throughput, and Overall Equipment Effectiveness (OEE).
Developed Excel-based data analysis and management tool to track production data.
Enabled production rate to meet 100% of the annual demand (70,000 transmissions).

Designed and modeled a pedal mechanism.
Executed functional proto-typing to analyze the design performance.
Performed Root Cause Analysis (RCA) for the weld failures and executed corrective actions for the fabrication of the pedal.