Sathish Manoharan
Austin
Summary
Senior Project Engineer with 3 years of experience in executing and managing mid to high-budget projects. Proven track record of delivering projects on time through meticulous planning, technical design, and adherence to deadlines. Strong problem-solving skills facilitate effective collaboration with teams to ensure seamless project operations.
Overview
4
4
years of professional experience
1
1
Certification
Work History
Senior Project Engineer
Abbott Diabetes Care - Freestyle Libre 3
Austin
11.2023 - Current
- Managed critical part obsolescence to improve equipment availability, reduce downtime, and control costs, boosting Overall Equipment Effectiveness (OEE).
- Led RCA initiatives to identify and eliminate failure modes, improving production efficiency by 15%, and reducing defect rates by 5%.
- Resolved glue dispensing jetting device charring issues through Fishbone RCA, enhancing equipment reliability and uptime.
- Directed a DMAIC initiative to eliminate micro-stops on a critical SMT line, targeting a 60-million-unit annual production capacity.
- Led the IBE program with Rockwell Automation, ensuring critical spares availability to reduce unplanned downtime, and enhance asset reliability.
- Coordinated with cross-functional teams for resource planning, engineering design, and contractor management to support project goals.
- Prepared and delivered project status reports to stakeholders, aligning project milestones with organizational objectives.
Senior Reliability Engineer
Ecobat Resources, Inc
Middletown
02.2023 - 10.2023
- Achieved 95% preventive maintenance completion, significantly reducing system downtime by 15%.
- Conducted critical asset assessments, enhancing runtime and reliability through implementation of HASS for roller bearings.
- Integrated CMMS with SAP to automate parts ordering, improving inventory management efficiency.
- Executed design studies and DFMEA for screw conveyor, optimizing inclination and flight variations for better bulk transfer.
- Performed failure analysis on oxy-fuel burner components, resolving ignition issues to improve system reliability.
- Increased hammermill uptime by 20%, scaling production capacity by 160,000 lbs. of raw feed daily.
Senior Reliability Engineer
Eli Lilly & Company
Branchburg Township
10.2021 - 01.2023
- Developed mechanical integrity programs for fixed equipment using NDT and ultrasound testing, extending service life and reducing failure risk.
- Optimized asset reliability through criticality assessments, improving inventory management, maintenance prioritization, and equipment performance.
- Executed FMEA for pressure vessels and process tanks, enhancing safety, product quality, and cGMP compliance with targeted inspection programs.
- Applied PDCA cycle to resolve clean steam generator leaks, reducing downtime through material analysis and targeted remediation.
- Conducted reliability testing (thermal aging, mechanical stress) on elastomers, reducing waste, resolving gasket and bearing issues, and increasing MTBF.
- Resolved vibration issues in ultra-pure water systems and WFI stills, implementing corrective plans to improve asset longevity and reliability.
Education
Master of Science - Project Management
University of the Cumberlands
Florence, KY01.2025
Master of Science - Manufacturing & Industrial Engineering
Rochester Institute of Technology
Rochester, NY01.2021
Skills
Team leadership and project management
Budgeting and finance
Client and vendor relations
Inventory management
Problem solving and troubleshooting
Data-driven decision making
Six Sigma and quality assurance
Certification
- Six Sigma Green Belt (CSSC)
- Certified maintenance and reliability professional (CMRP)
- Project Management Professional (PMP - PMI)
Timeline
Senior Project Engineer
Abbott Diabetes Care - Freestyle Libre 3
11.2023 - Current
Senior Reliability Engineer
Ecobat Resources, Inc
02.2023 - 10.2023
Senior Reliability Engineer
Eli Lilly & Company
10.2021 - 01.2023
Master of Science - Project Management
University of the Cumberlands
Master of Science - Manufacturing & Industrial Engineering
Rochester Institute of Technology
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