Karan Chaudhary
Ladson,United States
Overview
13
13
years of professional experience
Work History
Senior Controls Group Leader
Charleston Turbo Plant, Cummins Inc
12.2023 - Current
- Team Management - Manage the controls team for the assembly and test department, enhancing team effectiveness and operational efficiency.
- Strategic Project Leadership - Lead several significant capital projects on assembly lines: Diffuser plate fastening automation/ Component direct part marking/ Data plate loading mechanism/ SCADA-MES upgrade projects. Total annual savings - $750k.
- Operational and Strategic Improvements - Restructured controls team schedule for optimal onsite coverage/ Create and implement an obsolescence strategy with multiple hardware upgrade projects: Kinetix servo, SCADA, and automation communication upgrades/ vision and safety system upgrades.
- Training and Development - Groomed and trained technicians to enhance offsite support capabilities.
- Capital Planning - Collaborated with leadership to scope out potential projects and capital requirements for 2025.
- Six Sigma Projects - Finished goods reintroduction Six Sigma project, achieving a 50% reduction in scrap quantity and saving $225,000 annually in scrap costs.
Senior Manufacturing Engineer
Charleston Turbo Plant, Cummins Inc
06.2022 - 12.2023
- Led new product release project on Lambda Assembly line - total of 150 new turbocharger assemblies released for production.
- Led continuous improvement projects - locktite dispense quality improvement, diffuser press RFT improvement, new IPVs - component verification using vision systems.
- Inventory accuracy/control - Upgraded MES system transactions to improve finished goods inventory accuracy from 70 to 95%.
- Tooling upgrades - Enhance tooling for product end of line testing.
- Led capital projects for process improvements - cycle time reduction 15%, ergonomic improvements 20%, contactless gauging.
- Led site digitalization project to improve WIP job traceability, OEE and MTTR.
Controls Engineer
Charleston Turbo Plant/ Cummins Inc
02.2021 - 06.2022
- Controls/ME production support for Turbo Assembly/Test Lines.
- Maintain, Modify and Redesign SCADA platform to improve quality, safety, operations and profitability.
- C++ scripting for SCADA interface and query execution to manage MES data proficiently.
- Develop control systems for continuous process improvement.
- Mentor the Maintenance Team to improve Mean Time to Repair.
Test/Controls Engineer
New Electrified Power Business/ Cummins Inc
08.2020 - 02.2021
- Test/Controls production support for Battery Pack Assembly Line
- IOT project/ .NET framework: Develop custom in house TCP server and SCADA application on .NET framework to capture process data and display analytics on PowerBI for LV Welding unit
- End of Line Testing: Upgrade the Sytech Test bench to test the Engineering Product improvements for PD7000 Edison product Thermal Management System and High Voltage Module
- End of Line Testing: Develop a troubleshooting guide for Rover/Goodwood NHR testers for Maintenance team
- LabVIEW data acquisition: Develop a LabVIEW application to monitor potting process for Low Voltage battery packs
- Cognex vision system: Improve RFT numbers for 8250 battery line.
Six Sigma Project Manager
Heavy Duty Machining/ Cummins Inc
02.2020 - 08.2020
- Six Sigma Project - Improve traceability and analytics for in process quality checks on sub assembly line for machined 15L cylinder heads
- Cobot Integration - Complete in-house robot integration and tool development to clean metal shavings and washing solution from blind holes.
Operations Team Manager
Seymour Engine Plant/ Cummins Inc
08.2019 - 02.2020
- Monthly scrap reduction from 38% to 23% for Custom Machining department
- Scraps from part setups reduced from 19% to 6%
- Reduce bottleneck on asset 9206/9214: Work on 5-day production demand to build stock for machine maintenance downtime and meet On Time Delivery
- Reduced 5-day production sheet from 224 items to 25 items
- Manage a team of 16 associates, schedule daily production runs, e-time management and continuous improvement projects
- Mentor team associates and conduct performance evaluations.
Global Manufacturing Engineer
Columbus Engine Plant/ Cummins Inc
03.2019 - 08.2019
- Siemens PLC Software Training Package Development: .NET application / 74 Modules and 14 videos (1 hour) including basic hardware connection to Industry 4.0 applications
- Industry 4.0 Network Architecture: Define a network architecture in MEDC for communication between PLCs/field devices and Cummins data servers for a health monitoring/diagnostic/machine learning tool
- Siemens PLC Interface with 3rd Party Equipment Feasibility: Define a program/code architecture in MEDC/stand-alone modules for connection of Siemens PLCs to 3rd part devices and document generic process to maximize the PLC usage and build a custom control hub.
Maintenance Engineer
Torm PLC
10.2011 - 07.2016
- Lead a team of maintenance techs/electricians for planned and breakdown maintenance
- Manage inventory and supply of spare parts, carry out Risk Assessment /Job Hazard Analysis for various maintenance tasks
- Manage Fuel Oil Purification/ Waste Cleaning System/ Exhaust Cleaning System and Power Generation Units.
Education
Masters in engineering Controls -
Rochester Institute of Technology/ NY
12.2018
Skills
- Employee Development
- Continuous Improvement
- Project Management
- Capital Planning
Accomplishments
- Components Business Unit Automation Council Member - governing body for all automation capital project across 13 sites.
- Cummins North America Ergo Cup Winner, 02/2020, 08/2020, Automated blind hole cleaning application on machined parts
- Cummins Rapid Co-bot Deployment Program, 02/2020, 08/2020, First in Co-bot deployment program.
- Cummins Manufacturing Development Program Certificate, 03/2019, 02/2021, Two-year career development program
- Merit Scholarship - Rochester Institute of Technology, 07/2016, 12/2018
Timeline
Senior Controls Group Leader
Charleston Turbo Plant, Cummins Inc
12.2023 - Current
Senior Manufacturing Engineer
Charleston Turbo Plant, Cummins Inc
06.2022 - 12.2023
Controls Engineer
Charleston Turbo Plant/ Cummins Inc
02.2021 - 06.2022
Test/Controls Engineer
New Electrified Power Business/ Cummins Inc
08.2020 - 02.2021
Six Sigma Project Manager
Heavy Duty Machining/ Cummins Inc
02.2020 - 08.2020
Operations Team Manager
Seymour Engine Plant/ Cummins Inc
08.2019 - 02.2020
Global Manufacturing Engineer
Columbus Engine Plant/ Cummins Inc
03.2019 - 08.2019
Maintenance Engineer
Torm PLC
10.2011 - 07.2016
Masters in engineering Controls -
Rochester Institute of Technology/ NY
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