Rahul Laxman Iyer

+1-623-570-2848 rahulduong@cox.net LinkedIn.com/in/RahulIyer SKYPE ID: thaiduongco U.S. Citizen OCI (India) US Primary Residence Vietnam Secondary Residence

QUA LITY & PRO CESS ENGINEERING LEA N MA NUFA CTURING NEW PRO DUCT DEVELO PMENT

Quality & Engineering Leadership

Talented project leader and accomplished engineer with a strong background in quality management, process improvement, lean manufacturing, and new product development and launch. Certified Quality Engineer with a solid history of cost, time, and quality intervention strategies leading to process excellence and new business opportunities. Exceptional written and interpersonal communication skills foster clear and accurate communications, reports, and presentations at all organizational levels. Multilingual global citizen with native English fluency.

Quality & Project Management Lean Manufacturing, Six Sigma, Toyota Production System Continuous Improvement, Kaizen DoE, DFMEA & PFMEA, 8-D New Product Development & Launch Metallurgy & Machining (Ferrous & Non-Ferrous) Capital Expense & Budgeting QS 9001, AS 9100, ISO 9001, TS 16949, ISO 14000, OHSAS 18001 Safety & OSHA Standards Statistical Analysis (Parametric & Nonparametric) Root Cause Analysis & Failure Remediation ANSI J-STD-001C & IPC 610 requirements for soldering Quality & Performance Measurement Geometric Dimensioning & Tolerancing (GD&T) Corporate & Regulatory Compliance International Manufacturing Operations - SE Asia & Latin America Strategic Planning & Goal Achievement Non-Destructive, Destructive Testing, Metrology & Optical UL, CSA, ETL, RoHS, REACH Certification Metrology (LDV, PIV, Speckle Shearing, Shearography)

EDUCATION, CERTIFICATION & PROFESSIONAL DEVELOPMENT, LANGUAGE SKILLS Master of Science in Engineering, Mechanical Engineering Western Michigan University, Kalamazoo, MI

Bachelor of Science in Mechanical Engineering Rose-Hulman Institute of Technology, Terre Haute, IN

Certified Quality Engineer (CQE), Certification #63672 American Society of Quality (ASQ)

Project Management Professional (PMP), anticipated April 2016 Project Management Institute

Value Analysis/Value Engineering Argo Consulting

Six Sigma Black Belt Certification Dana University Technical School

Internal Auditing to the ISO/QS 9000 Quality Standard Tooling & Manufacturing Association

Fundamentals of Engineering Exam/Engineering Intern (FE/EI) State of Indiana

Asian Corporate & Entrepreneur Leaders (ACEL) Active member and mentor; Tempe AZ Chapter

Toastmasters International Active member, Sergeant-At-Arms, Maverick Toastmasters, Mesa AZ Competent Communicator Certification; Competent Leadership Certification in progress.

Language Skills: English (native), Spanish (proficient), Russian and Vietnamese (beginner), Tamil-India (rudimentary)

LEAN MANUFACTURING, PROJECT MANAGEMENT, STATISTICAL ANALYSIS & VALUE ENGINEERING Lean, A3 Methodologies, Why-Why Analysis/Fishbone Analysis, 8-D, MTTF, MTBF, MTBE, MTBCE, DMAIC/Six Sigma, PPAP/IPDS/Toyota Submissions/ISIR/FAIR/FAT/LAT, APQP/ANPQP, Pokayoke, MSA; Technical FAST diagrams, Time Studies, Cost/Benefit Analysis & Payback, Focus Factory, Gage R&R, DoE (Taguchi, Shainin, Classical), PERT/CPM, Toyota Production System (TPS), Process Control Plans, P-FMEA, Value Stream Mapping (VSM), Process Flow Diagrams (PFD)

APPLICATIONS & PROGRAMMING LANGUAGES Project Management (Microsoft Project, Primavera, EVM) CAD (C3P, AutoCAD, Mechanical Desktop, CADAM, CADkey, Pro/Engineer, SDRC I-DEAS Master Series, Alibre Design, CATIA, Solidworks) Programming Languages (C++, FORTRAN, Motorola 6802/6811 Assembly Language, CNC/G-Code/M-Code) Statistics/Analysis (MINITAB, Maple VR4, MathCAD, SAS, JMP) Microsoft Office (Visio, MS ACCESS & SQL Queries, Word, Excel, PowerPoint) Graphics (SmartDraw, COREL Draw) ERP/MRP (Filemaker Pro, Solumina, SAP, Team Center, AS 400) Oracle/AGILE (BOM, BOD, Routings, Queries, ECO, ATO, Labor Routings) Lotus 1-2-3, WordPerfect

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PROFESSIONAL EXPERIENCE

NAMMO TALLEY, INC. Mesa AZ 2014 – 2015 Program Quality Engineer

Quality Management of Shoulder Launched Munitions (SLM) Manufacturing (M141 Bunker Defeat Munition, M72 Rocket Launcher, M72 FFE Rocket Launcher, SMAW Ammunition).

Quality management and process development for Shoulder-Launched Munitions Program contracts valued at $10M.

Delivered $60K in savings through implementation of Statistical Process Control (SPC), Process Control Plans (PCP), and FMEA as part of process development.

Interface with United States Defense Contracts Management Agency (DCMA) & Overseas Customers for Shoulder Launched Munitions (SLM) programs

AS 9100: Contract Review, Quality aspects of a Federal Contract, Letters of Instruction (LOI) and Letters of Delegation (LOD) for US Government Contracts, Contract Delivery Requirements List (CDRL) items tied to Federal Contracts, Basis of Estimates (BoE's) for Federal Contract Solicitations, First Article Tests (FATs) and Lot Acceptance Tests (LATs) for manufactured products.

Application of MIL-STD-1168, DI-MISC-80043 Ammunition Lot Numbering and Ammunition Data Card / Submission of Ammunition Data Cards into Worldwide Ammunition-data Repository Program (WARP).

Application of ANSI Z1.4 / Z1.9 Methods for Acceptance of Product / Application of MIL-STD-1916, DOD Preferred Methods for Acceptance of Product.

ABB SOLAR GROUP LTD (Formerly Power-One Renewable Energy Solutions LLC) Phoenix AZ 2010 – 2013 Senior Manufacturing Engineer

Led teams of 4-25 for NPI Projects/Launches and continuous improvement projects including new plant production startup in North America and Australia for electronics assembly on renewable energy power inverters.

Managed 23 new production introduction (NPI) launches valued at $45M:

Photovoltaic String Inverters (2.5 KW to 20 KW), Photovoltaic Central Inverters (50 KW to 1.3 GW), Monitoring equipment (Weatherstations, Combiners, and System Managers), Printed Circuit Board Assembly (PCBA).

Automated processes in line, moving from manual assembly to automated assembly.

Reduced nonconformances by 30% and increased final packout throughput by 20%.

Improved quality-cost-delivery through application of value analysis and value engineering.

Conducted process mapping and made recommendations on component, product, processing improvements to meet specifications for plants in Europe and Asia.

Developed work instructions/MOTs, procedures, production processes; trained production teams.

Specified, developed, and procured capital equipment.

SHORT-TERM CONTRACT QUALITY AND PRODUCT DEVELOPMENT ENGINEERING LEADERSHIP ROLES 2009 – 2010 Manufacturing Engineer Process Engineer

Delivered reduction of 1.25 labor hours per vehicle through cost justification for module and process redesign on Honda Van retrofit. Led Teams of 4-25 on Gen4 NPI launch & continuous improvement projects as a Manufacturing/Process Engineer for Vantage Mobility International, LLC.

Increased availability in wax injection by 5% through leadership of continuous improvement and process development initiatives for investment casting foundry. Implemented Statistical Process Controls and proposed capital improvements as Principal Process Engineer for The Timken Company.

Led teams of up to 5 operators and supervisors in venturi air valve redesign, prototyping, continuous improvement, process flow, work instructions, process mapping, P-FMEA, Control Plan. Led engineering initiative on D-FMEA development as Mechanical Engineer for Triatek Holdings, LLC.

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TEPRO INDUSTRIES INC. (Nissan Motors Manufacturing North America affiliate) Winchester, TN 2006 – 2009 Quality/Process Engineer

Project manager and launch lead on rubber seal programs with mandate to address quality and profitability issues. (Nissan Altima/Maxima/Armada/Pathfinder/Quest/Frontier and Chrysler 300/Dodge Magnum).

Delivered $45K in annual savings for operations: Lead Kaizen (process improvement) activities in Final Assembly areas of plant (total of 4 full-time production operators removed from process. Able to remove redundant inspection of finished product (removal of 200% inspection)

Delivered $48K in annual savings with supplier development activities including logistics optimization, quality control training program development, and parts qualification and low cost international transport. Developed testing, rework, and sorting methods for supplied components, including visits to the supplier to develop countermeasures and foster process improvement. Included developing suppliers in Asia.

Championed resolution of customer quality concerns using Why-Why Analysis, Honda 5P, and Daimler-Chrysler 7 Steps of Problem solving; trained Production on QA and investigation techniques.

Worked with manufacturing to develop and implement pokayokes in extrusion and finishing processes.

Collaborated with overseas suppliers on development of control plans, quality standards, and P-FMEAs; reviewed, revised, and developed Standard Work Instructions (SOPs), Control Plans, Quality Standards, P-FMEAs meeting Renault Nissan Alliance (RNA) Standards and TS 16949 Standards.

AISIN MANUFACTURING ILLINOIS LLC (Toyota Motors Manufacturing North America affiliate) Marion, IL 2005 – 2006 Quality/Process Engineer

Launch Lead Project Manager for Toyota Sequoia, Sienna, and Lexus RX 350 powered door assemblies and powered backdoor assemblies, and General Motors Sunroof Modules.

Saved $60K annually applying Taguchi DoE methods to resolve issues with powered door unit; led Process Change Requests and PPAPs for implementation of Engineering Change Instructions per Toyota SQAM.

Championed resolution of customer quality concerns using Why-Why Analysis, Toyota 8 Steps of Problem Solving & A3 Methodologies; trained Production on QA and investigation techniques.

Collaborated with overseas suppliers on development of control plans, quality standards, and P-FMEAs; reviewed, revised, and developed Standard Work Instructions (SOPs), Control Plans, Quality Standards, and P-FMEAs meeting Toyota Inspection Standards and TS 16949 Standards.

DANA CORPORATION Sterling, IL 2003 – 2004 Process Engineer Six Sigma Black Belt

Project Manager on new driveshaft production launch for five different series of driveshaft. Accountable for tooling development, project timeline, and collaborating with Purchasing Manager on component sourcing. Customers included Caterpillar, Case New Holland, John Deere, and US & Foreign Military.

Project delivered $4.2M in annual new business and saved $150K annually with warehouse closing.

Led team of 20 production plant employees in Value Stream Mapping; established Rapid Baseline among lines of Dana Production Systems (DPS); identified 11 Black Belt and Kaizen training opportunities. Generated information used to develop foundation, set priorities, and coordinate lean activity for fiscal year.

Coached ISO 14000/OHSAS 18001 Coordinator and Quality Manager in Lean Concepts, Kaizen, 5S Techniques, Statistical & Analytical Techniques, and Six Sigma leading to successful Green Belt certification.

Six Sigma Black Belt, Kaizen, & Kanban Training delivered $770K annual savings: Conducted training programs leading to efficiency improvements in manufacturing and Worker’s Compensation management.

Axle redesign delivered 42% production cost reduction for $150K annual savings: Applied Value Analysis & Value Engineering principles to axle redesign to reduce production cost from $170 to $290 per part.

Designed and developed tooling, fixturing, and assembly processes for new product introductions and managed reconditioning and calibration. Worked with overseas tooling suppliers on fixturing development.