ARUN KUMAR

COPPELL TX 75019
(PHONE) 972.501.0010
EMAIL: ak70a992@westpost.net
MASTER BLACK BELT - QUALITY ASSURANCE
Proactive, change agent with 16 years of experience in Quality, Reliability, and
Six Sigma Process, including Lean Events, leading development and implementatio
n of strategies that support organizational operating, financial, and quality ob
jectives. Skilled Continuous Improvement Leader in the DMAIC Problem Solving me
thodology, providing training, mentoring and coaching to both Black Belt and Gre
en Belt candidates at all levels within the organization from hourly associates
to plant management. Change agent facilitator of Lean Manufacturing activities,
leading teams to achieve sustainable results, resolving conflicts, and building
consensus.
- ASQ CQM, CQE, CRE, CQA, CQIA, CSSBB and CSSGB certifications. 2004 Cumulative
ASQ Certification Award among Top 5% ASQ.
- Gold Medal for Best Outgoing Student and highest GPA in BS Degree.
Systems Engineering / Reliability
Six Sigma Black Belt
Root Cause Analysis (8D, 5-Phase)
Team Building/Mentoring
Cost Saving Initiatives
Project Manager
Lean/Kaizen Facilitator
Design for Six Sigma
Design of Experiments
PROFESSIONAL EXPERIENCE
BELL HELICOPTER TEXTRON / AAI CORPORATION, Fort Worth, TX 2004-2010
Bell Helicopter is a leader in the global helicopter industry and the pioneer of
tiltrotor aircraft, and is a wholly owned subsidiary of Textron Inc.
Master Black Belt / Black Belt / QAEngineer Specialist
- Directed Black Belts and Green Belts enterprise-wide towards project completio
n and served as mentor. Mentored several DFSS / DMAIC projects to support opera
tions, sytems engineering, etc.
- Supported Six Sigma Deployment including development of Green and Black Belts,
facilitator of Kaizen and 5S, introduction of DMAIC tools in decision making pr
ocess, including PFMEA, 8D, VSM and Statistical Analysis (Minitab).
- Develop and document the business case for key continuous improvement initiati
ves that identify hard financial and customer service benefits and gain business
and executive leadership buy in.
- Support, mentor and develop Green Belts in the Six Sigma methodology and ensur
e/certify Green Belt project closure.
- Train and develop employees in application and use of a variety of performance
improvement tools such as DFSS/DMAIC as well as application of Lean & Six Sigma
tools by acting as a Process/Lean Six Sigma subject matter expert.
- Guide teams with corrective action plans, tracked results and followed-up to e
nsure timely closure of corrective actions, including process, product and syste
ms audits, as well as internal audits for compliance with customer mandated Qua
lity Management Systems.
NOTABLE ACHIEVEMENTS
- More than 10 million dollars savings and earned Top Performer at Enterprise Le
vel three (3) consecutive years with more than 40 six sigma projects to improve
quality, reduce cost and support customer needs.
- Mentored Black Belts and Green Belts to certification. Certified 38 Green Bel
ts and 4 Black Belts at all levels.
- Key Executive member of Six Sigma Council to support organization six sigma de
ployment and change management.
- Trained more than 75 Green Belts per year and Lead Instructor / Trainer for Si
x Sigma Green Belt Program within AAI Textron Six Sigma organization.
AMX CORPORATION, Richardson, TX 2002-2004
AMX is a control technology company that provides hardware and software solution
s to simplify the way people interact with technology.
Quality & Reliability Engineer
- Reliability prediction and support new product roll out on innovative control
systems.
- Support Supplier Quality Engineering efforts and provide enterprise wide quali
ty support for internal quality inspection and execution of quality plans.
- Act as a proactive quality resource to partner with operations managers to ide
ntify, plan and implement process improvement solutions, guiding use of failure
analysis at enterprise level.
NOTABLE ACHIEVEMENTS
- Reduced average incoming defects by 25% with all contract manufacturers, resul
ting in 15% On-Time delivery to end customers.
- Developed contract manufacturers to correct nonconforming incoming product shi
pments, including on-site auditing of vendor facilities.
- Established visual acceptance limits, Standard Work Instructions, PFMEA, Contr
ol Plans, Process Flow Diagrams for New Product Launch.
- Established Quality Test Lab for incoming receiving inspection, development of
written procedures compliant with AMX Engineering standards, composure of Stand
ardized Work Instructions from training and routine test practices.
MARCONI TELECOM/JABIL CIRCUITS, Bedford, TX 2000-2002
Marconi specializes in Telecommunications Services and support end customers. J
abil is a provider of electronic manufacturing services, and designs and manufac
tures electronic circuit boards for major OEMs including Telecommunication provi
ders.
Quality Engineer
- Key member of the transition team involved in Marconi Communications to Jabil
Circuit Inc., transition, accountable for producing performance reports.
* Instituted quality metrics such as DPMO, DPM, and other productivity measu
res and used statistical data collection system (CDACS).
* Presented analysis of the data to both internal and external customers.
- Performed FMEA on the product test failure and applied reliability prediction
techniques to identify root cause at Jabil Circuit. This resulted in increased
business and 20% improved profits.
- Re-engineered and streamlined to improve productivity of Marconi Communication
s/Jabil Circuit by $2.5 M per year. Modified business process, improved layout,
in addition to creating best practices.
- Consistently achieved quality metrics such as DPMO and DPM through the use of
quality improvement tools such as 8D problem solving technique at Jabil Circuit.
NOTABLE ACHIEVEMENTS
- Work with teams on end-to-end process improvement projects and provide expert
support while facilitating and tracking team progress of tool usage, change mana
gement, root cause identification, and process improvement methodology. Ensure
appropriate controls are in place to monitor and maintain results and foster con
tinuous improvement.
CORNING CABLE SYSTEMS, Keller, TX 1999-2000
Corning Cable Systems LLC is part of Corning Incorporated's Telecommunications s
egment, and offers the broadest range of end-to-end fiber optic and copper produ
ct solutions for telecommunications networks.
Quality Engineer
- Reduced 20% defect rate in Optical Hardware, Connected & Fab Shop manufacturin
g assembly.
- Generated quality plans for new products and implemented quality metrics for m
anufacturing, development and marketing departments.
- Initiated a team effort to perform Failure Mode and Effect Analysis (FMEA) on
MTRJ, First Link, and Field Installable 12 Fiber MTP Connector new product devel
opment.
NOTABLE ACHIEVEMENTS
- Conducted FMEA & design of experiments at Citation metal forming process yield
ing a cost savings of $500 K at Corning Cable Systems.
TELEDYNE CASTINGS SERVICE, LaPorte, IN 1995-1997
Teledyne Castings Service is a diversified manufacturing company serving global
markets with specialty metals, aerospace, electronic, industrial, and consumer p
roducts.
Quality Control Manager / Metallurgist
- Re-engineered the Teledyne Inc. manufacturing process and designed the wire in
jection systems, resulted in cost savings of $750K per year.
- Implemented recycling programs at both Teledyne Inc. & Wagner Castings Co. met
al forming processes, resulted in cost savings of $800 K per year.
- Designed and developed and automated model at Teledyne Inc. for identifying du
ctile and gray iron charge makeup using Visual Basic. This model resulted in ra
w material savings of $25K per year.
NOTABLE ACHIEVEMENTS
- Conducted FMEA & design of experiments in collaboration with GE Engine Blocks
(Customers) to yield a cost savings of $2.5 million and 30% increased business.
- Worked with Production and Materials personnel to resolve issues pertaining to
drawing interpretations, acceptance criteria, engineering changes, rework and m
anufacturing specifications.
- Served as first line of contact to assist when issues arose at production faci
lity.
- Initiated requests for corrective action from suppliers in resolving nonconfor
ming product issues.
WAGNER CASTINGS, Decatur, IL 1994
Manufacturer for Automotive ductile and gray iron castings
CMM Inspector / Metallurgist
FUSION WELDING ELECTRODE, Chennai, India 1991-1992
Welding Electrode Manufacturing Company
Service Engineer
EDUCATION AND RELATED CURRICULUM
M.S., Manufacturing Engineering, Bradley University, Peoria, IL
B.S., Metallurgical Engineering, PSG College of Technology, Coimbatore, India
Certified Black Belt through American Society for Quality
Master Black Belt and Certified Black Belt through Textron Six Sigma
VARIOUS QUALITY RELATED COURSES
Design of Experiments, PFMEA, Process Walk, 8D Problem Solving, Lean Manufacturi
ng Value Stream mapping, GD&T, ISO9000 Internal Auditor Training.