BALAJI VARMA GUNDLA

• Identified and implemented cost-saving opportunities across manufacturing processes, resulting in a15% reduction in production costs by optimizing material flow and reducing waste through Lean principles
• Utilized PDCA and DMAIC methodologies to analyze workflows, reducing cycle times by20% and increasing overall productivity by25%
• Designed and optimized manufacturing processes for the Dexcom Needle Hub Assembly to improve efficiency and reduce production costs
• Implemented HMI (Human-Machine Interface) solutions to enhance user interaction and streamline operation across a12-station automated assembly machine
• Coordinated robot actions and sequences using PLC (Programmable Logic Controller) integration, optimizing cycle times and minimizing downtime
• Conducted time studies to determine standard work, accurately forecast workforce needs, and optimize labor allocation for cost-effective operations
• Executed Lean tools such as value stream mapping, line balancing, and5S to identify and eliminate process inefficiencies, driving a15% reduction in operational costs
• Developed and standardized visual Standard Work documentation, improving material handling consistency and aligning processes across teams, resulting in smoother operations and cost-effective handling procedures
• Designed and implemented Poka-yoke systems, reducing operator errors by12% and increasing first-pass yield by15%
• Led the integration of automated systems into the production line, enhancing precision and throughput of needle hub assembly by80%
• Led5S initiatives across manufacturing lines, improving workstation layouts and operator efficiency, reducing downtime by10%, and increasing safety compliance
• Developed and implemented warehouse layout solutions to optimize storage, pick paths, and transportation routes, ensuring compliance with safety protocols and ergonomic standards to enhance worker comfort and productivity
• Implemented Quality Control Plans (QCPs) and Layered Process Audits (LPAs), achieving a20% reduction in defects and enhancing process consistency
• Spearheaded cross-functional teams to address bottlenecks using DMAIC and Lean Six Sigma techniques, resulting in a30% increase in throughput and a20% reduction in defects
• Developed and maintained PFMEA and process control plans, improving process capability from1.2 to1.5
• Identified and eliminated waste through Kaizen events, reducing cycle time by18% and increasing throughput by30%
• Evaluated and maintained capital equipment, ensuring minimal downtime through proactive maintenance schedules and extending the lifespan of critical manufacturing equipment by15%
• Led safety initiatives, ensuring compliance with OSHA standards and improving workplace conditions through proactive audits and employee engagement
• Implemented CAPA processes, ensuring compliance with ISO standards and achieving a15% reduction in customer complaints
• Utilized Lean Six Sigma techniques, including A3 problem-solving and5S methodologies, to identify inefficiencies and implement process improvements, resulting in a25% increase in productivity on the assembly line
• Applied quality tools and statistical techniques, including FMEA, SPC, control charts, process capability, and RCCA, to enhance process efficiency and product quality

• Create, Review, and execute IQ/OQ/PQ
• Installation Qualification/ Operating Qualification/Performance Qualifications
• Involved in creating templates for the summary reports
• Worked in risk management documents using tools such as DFMEA
• Conduct Gap Analysis, Change Control, and GxP Assessment
• Participate in devising and implementing a revalidation program
• Involved in Operation Qualification using thermocouple calibration and Temperature mapping of equipment like autoclaves, incubators, freezers, refrigerators, ovens

• Conducted routine inspections and preventive maintenance on Caterpillar and Volvo machinery, including Excavators, Loaders, Dumpers, Drilling machines, and Dozers, to ensure optimal performance and reduce downtime
• Managed an inventory of over500 spare parts for Caterpillar and Volvo equipment, ensuring a98% parts availability rate for maintenance and repairs
• Managed project timelines and budgets for equipment ramp-ups, reducing launch costs by12%
• Assisted in the complete overhaul of key components in Caterpillar and Volvo machinery, enhancing the longevity and reliability of critical equipment used in infrastructure projects
• Diagnosed and repaired mechanical issues in heavy equipment, including hydraulic, pneumatic, and electrical systems, minimizing equipment failure and ensuring continuous operation
• Analyzed performance data of Caterpillar and Volvo machinery and provided recommendations for optimizing operational efficiency and extending equipment lifespan
• Calculated manpower requirements using MOST techniques, optimizing labor allocation by10%
• Prepared detailed maintenance reports for Caterpillar and Volvo equipment, documenting repairs, parts used, and time taken for each task, aiding in efficient project management and future maintenance planning

• Collaborated with network architects to enhance the current infrastructure, resulting in an18% improvement in overall network efficiency
• Directed thorough testing and validation of new configurations, reducing post-deployment troubleshooting by21%
• Took a vital role in selecting and procuring new networking equipment, negotiating contracts that lowered equipment costs by6%

• Analyzed braking needs considering weight, terrain, and rider preferences for top-notch performance and durability
• Utilized AUTOCAD and SOLIDWORKS to design3D models, ensuring brake system components meet ATV specifications through simulations
• Created advanced ATV braking systems, improving efficiency by20% and ensuring safer riding
• Optimized existing designs, reducing production costs and enhancing overall performance.
• Streamlined the design process for increased efficiency by utilizing advanced CAD software tools.

• Merit Scholarship.
• GPA: GPA3.3

Award winning automotive project – FMAE BAJA.

• Member of SAE BAJA.
• Completed professional development in DMM