BALAJI AKKAYYAGARI
Summary
Results driven Mechanical engineer with 3+ years experience in design, manufacturing and quality across regulated and high precision industries. Expertise in 3D CAD Design, GD and T, tolerance Analysis, and Process optimization. Proven track record of reducing lead time, improving quality, and designing complex assemblies. Experinced in Lean manufacturing, root cause analysis, pFMEA, Validations, and cross functional collaboration to drive measurable improvement. Currently seeking to bring my experience into a long term position and create meaningful impact.
Overview
3
3
years of professional experience
Work History
Manufacturing Engineer
Phillips Medisize
Costa mesa, USA
08.2024 - 12.2025
- Developed 2D drawings and review DFM/DFA. Performed stack up analysis and improved the production efficiency by 16%.
- Designed fixtures and tools to aid the operators and inspector for fast production and proper inspection.
- Skilled in ASME Y14.5 GD and T and tolerance stack ups.
- Created IQ/OQ/PQ validation protocols, GRR, DOE, pFMEA, control plans and CAPAs.
- Experienced in applying lean manufacturing principles and six sigma tools.
- Written work instructions for assembly, and Manufacturing. Resolved a persistent engineering problem by modifying the WIs based on the DWGs.
Manufacturing Quality Engineer
Advanced Bionics
Valencia, USA
01.2024 - 07.2024
- Creating and dispositioning non-conformance report and worked on CAPAs.
- Experienced in fishbone, 5 whys, 8whys, 8D problem solving techniques.
- Experienced in Minitab and SAP
- Worked in KAIZEN, Gemba, Poka-yoke, and value stream events. Reduced the lead time from 2 days to 1 day.
- Experienced in developing protocols, GRR study, DOE, IQ, OQ, PQ validation reports.
Mechanical Engineer
Omniscient Imaging
Tucson, USA
09.2023 - 12.2023
- Designed a Novel Endoscope and named inventor on patent.
- Re-designed the mechanics of a camera FOV and increased the range of angular motion from 90 degrees to 210 degrees.
- Designed the endoscope assembly based on the simulation results and created 2D drawings for manufacturing.
- Reviewed old drawings and bridged the gap between components and assembly drawings leveraging tolerance stack up.
Quality Engineer
Phillips Medisize
Costa Mesa, USA
09.2022 - 08.2023
- Experienced in root cause analysis, resolving the production line issues.
- Created test protocols and reports. IQ, OQ, and PQ. pFMEA, control plans, PPAP work books.
- Reduced the takt time from 40 min to 15 seconds using a python module.
- Created non-conformance reports, Determine product disposition, developed re-work instructions.
- Experienced in updating SOPs and site level WIs. Gap analysis.
- SAP experience
Education
MS - Mechanical Engineering
Wright State University
Ohio01.2022
Bachelors - Mechanical Engineering
IIIT RGUKT
India01.2020
Skills
- SolidWorks
- DFA
- DFM
- Tolerance Stack-up
- GD&T
- Lean Manufacturing
- Six Sigma
- PFMEA
- Root Cause Analysis
- SAP
- Python
- ANSYS
- ABAQUS
Timeline
Manufacturing Engineer
Phillips Medisize
08.2024 - 12.2025
Manufacturing Quality Engineer
Advanced Bionics
01.2024 - 07.2024
Mechanical Engineer
Omniscient Imaging
09.2023 - 12.2023
Quality Engineer
Phillips Medisize
09.2022 - 08.2023
MS - Mechanical Engineering
Wright State University
Bachelors - Mechanical Engineering
IIIT RGUKT