SUMMARY:

• Implemented reliable and cost effective Test Automation processes (with capacity for future expansion to support increased revenue forecast), tooling and preventive maintenance schedule for hardware/software
• Outsourced and Managed assembly, product testing and direct shipment to worldwide customers from Contract Manufacturer, based in USA, India, China and Mexico.
• Identified and Implemented cost reduction opportunities in the new products and at sustaining stage
• Implemented Special Hardware - Software Customization (labels-overlay - banner - Configurations etc for multiple customers per special specifications)
• Implemented and Managed reverse logistics-RMA warranty process in - house and at CM facility
• Completed six sigma Training and received Certification for “Lean Manufacturing” and “Green Belt”.
• Completed and received certification for “Process Validation” (IQ - OQ - PQ) from American Society for Quality (ASQ)
• Reduced or eliminated risk by studying Failure Mode and Effect Analysis (FMEA).

MS Office, Assembly and C language programming, PCI bus based LAN/WAN interfaces such as: T1/T3, E1/E3, ATM, Ethernet, Lab Windows/CVI National Instruments Application software, Expandable and Matrix ERP (enterprise resource planning software) BOM and change management systems, Arena, Agile product lifecycle management (PLM). Profit key, Epicor ERP Software, Ocuity, Clarity BOM management system.

PROFESSIONAL EXPERIENCE:

Confidential, Fremont, CA

Sr. Program Manager

Responsibilities:

• Direct Communication with medical, defense and aerospace customers to understand their requirements and expectations. Provide regular status updates to the customers. Ensure products are in compliance with ISO 9001, AS9100 and ISO 13485 standard as required.
• Provided leadership to cross functional team to setup and verify process flow to accomplish specific tasks to meet customer’s objectives.
• Worked with Quote teams to coordinate quotation activity on new business opportunities.
• Worked with cross functional teams for both; sustaining and New Product Introduction (NPI) projects management, including High Voltage system assembly, implementing new tools/Fixtures for NPI and on time delivery of sustaining products.
• Reviewed and implemented required process improvement based on pre and post DFM for NPI.
• Responsible for order management, build to order (BTO) and configure to order (CTO) products per customer agreements. Also manage RMA (Returned Material Authorization).
• Worked with customer’s engineering team to understand the new product requirement, new/alternate part qualifications for End of life parts, ECO/Deviations changes and plan for implementation.
• Resolved day to day business issues/concerns with customers while maintaining the customer satisfaction (in high 90% and on time shipment (in high 95%) of Quality products.
• Lead Lean and Kaizen initiatives for cell layout to improve process time and quality.
• Followed up on Supplier Corrective Action Report (SCAR) from customers and/or to our suppliers with Corrective and Preventive actions (CAPA).
• Reduced and/or eliminated risk for on time quality products delivery by anticipating potential problems and conducting Failure Mode and Effect Analysis (FMEA) during NPI processes.
• Worked with the customer for timely payment of Excess and Obsolete material.

Confidential, Santa Clara, CA

Staff Technical Operations Lead

• Managed three key suppliers: Sheet metal, Backplane Assembly vendor and Contract Manufacturer (CM). Evaluated suppliers to ensure quality products are shipped and identified ways to optimize manufacturing processes. Started shipment of quality products within 90 days.
• Managed Reverse Logistics Management (RMA) activities and on time shipment for advance replacement. Worked in conjunction with CM, sheet metal and components suppliers to resolve quality issues, lead failure root cause analyses and corrective-preventive actions (CAPA). Also prepared 8D reports for STOKE’s customers.
• Managed key suppliers, including qualifying first article. Evaluated suppliers to ensure quality products are shipped and identified ways to optimize manufacturing processes.
• Prepared and reviewed quarterly business report (QBR) of supply chain operations metrics to Supply Chain partners and operations teams.
• Monitored all manufacturing assembly and test processes at CM site, achieved yield quality to high 98%.
• Worked with Design team and implemented Design for Manufacturability (DFM) and Design for Testability (DFT) for new products (NPI); IP management card and 10 GigE line card. Prepared BOMs, implemented Engineering Change Orders (ECOs) for Bill of Materials (BOMS) and drawings, released it to production.
• Led CM to establish pilot runs, work flow, capacity and capability planning for new and sustaining products.
• Worked with CM to understand the potential problems -failure modes to implement counter measures to reduce or eliminate the risks.

Selected Accomplishments:

• Facilitated 300% revenue growth by initiating shipment of top-quality products in only 90 days. Utilized Agile PLM system and methodologies to maximize quality and efficiency.
• Defined and developed BOM structures for SSX-3000, 5 Rack Unit (RU) chassis, prepared all documentation, validated and received RoHs compliant certifications and worked with Mechanical Engineering to document drawings and released ECOs for all second source chassis BOMs and drawings.
• Lead cross functional teams for on time new products introduction of 10 GigE line card into manufacturing.
• Enabled release of new memory and other modules by managing qualification of modules from multiple suppliers (Viking, Net logic and Cavium) for end of life components. Worked with suppliers, contract manufacturer, internal software and hardware teams, and Operations Test team to conduct all required tests prior to release.
• Delivered consistently superior product quality by constantly reviewing quality yield data with CM and suppliers.
• Resolved non-conforming material reject (NCMR) issues and implemented corrective actions plan at suppliers.

Confidential, Fremont, CA

Technical Manufacturing Operations Leader

• Responsible for new product introduction, manufacturing test and assembly set up, test and potting equipment procurement, process optimization, and capacity/capability planning for Energy efficient Lighting product.
• Developed and maintained BOM structures, drawings, COST, ECR, and ECN processes using Arena PLM for product releases. Implemented product tree structure and integrated with change management system. Served as liaison during Initial Product Inspection audits. Developed ECR/ECO/Deviation process flow and procedures.
• Managed inventory transactions with 3rd party logistics provider, ran quality meetings with contract manufacturers and project meetings with design team, and maintained UL compliance certification.

Selected Accomplishments:

• Played a key role in transfer of production processes and ramp-up activities at new contract manufacturer with local (US) and off-shore (India) facilities.
• Optimized processes by conducting time and motion studies with contract manufacturer.
• Implemented cost-effective field installation processes, reduced expenses by $ 200.00 per unit installation.
• Ensured on-time build, testing, and shipment of beta, pilot, and release products by coordinating training of contract manufacturing (CM) staff and monitoring performance. Assured /validated the implementation of ECO released BOMs and drawings at vendors including CMs facilities
• Improved the quality of the product by monitoring yield data and reviewing field failures with contract manufacturing and provided corrective actions and also reviewed DFX and quality issues with development team.

Confidential, Santa Clara, CA

Product Engineering Technical Operations Leader

• First person in Operations group for a startup company. Managed all Manufacturing Operations for Startup Company for new product introduction with Automation test and built carrier-class chassis and unit-based secure routers with embedded controller modules.
• Lead and conducted cross functional team meeting with Engineering, Operations, Marketing and Sales, provided solutions to key issues to support New Product Introduction (NPI) releases on time.
• Responsible for DFX, resource planning, evaluation and procurement of equipment, tooling, manufacturing setup, design and development, hardware/software integration, test automation, documentation, and budgets.
• Provide project/program status - risk and mitigation plan to key senior management team on new products releases.
• Key member for ERP system evaluation and implementation for a startup company.
• Developed, Released and Maintained BOM, Engineering Change Orders (ECO) documents.
• Lead qualification of supply chain partner, PCB vendors, and contract manufacturers in US, Mexico, China, and India. Also negotiated contracts and terms agreements with them.
• Directed global supply chain operation and ensured compliance with Lean/Six Sigma, CMMI (Capability Maturity Model Integration) methodologies, and with ISO 9001 requirements.
• Qualified OEM and ODM design vendors for product testing and manufacture.
• Developed ICT and functional test specifications, ECO documents, served as liaison between CM, Sales, and Order Management.
• Managed design, development and implementation of all automated stress screening, Functional and system level testing for new product Introduction, and Total 36 Assembly part numbers.

Selected Accomplishments:

• Played major role in building company from initial startup to profitability, and acquisition by Nortel.
• Established top-performing manufacturing and product engineering teams in US and overseas.
• Lowered production costs by migrating all in-house manufacturing to contract manufacturers.
• Passed all quarterly audits and maintained UL-CE-TUV compliance for all products.
• Managed and achieved lowest reverse logistics RMA warranty returns (0.3%) in company through extensive first article acceptance testing, implementing corrective-preventive actions (CAPA) and implementation of Lean processes at contract manufacturers.
• Reduced test costs close to 80% and improved overall quality by automating testing processes.
• Delivered 100% yield at system level testing and better than 90% for in-circuit and board-level testing..
• Implemented Reverse Logistics /RMA warranty processes in-house and at Contract Manufacturing. Responsible for Root Cause of the System, Board, Logic, Circuit Failures and Corrective Actions.

Confidential

Test and Manufacturing Engineering Manager

• Responsible for planning, scheduling, department budget, product cost and execution of Manufacturing (Mfg.) and new product introduction processes for TI/EI CSU/DSU, T3/E3/ATM Broad Band Products.
• Early involvement with the design team during the new product development to ensure the design for Reliability, Testability, Manufacturability and for common modularity.
• Initiated Mfg Automatic test concept for the company.
• Provided technical guidance and supervised Test Engineers for the implementation of the Automatic Functional and system Test Developed Auto test for total of 8+ high volume products. Reduced the Test time and cost by 75% and improved the quality by removing human intervention.