Jaya Chandra Sekhar Ponnapalli
Manufacturing Engineer @Lear Corporation
Signup · Get unlimited contacts
WORK HISTORY
Manufacturing Engineer @Lear Corporation
Improved motor and inverter line throughput by 10% by conducting DOE using JMP to optimize dispensing parameters for highviscosity thermal paste application, including nozzle size, dispense pressure, ambient temperature, and robot travel speed. Reduced thermal curing-related defect rates by 15% by deploying SPC X-bar and R charts in Minitab, enabling real-time tracking of oven temperature zones and implementing automated alerts for process drift. Diagnosed recurring microstoppages in automated press-fit stations using SCADA time-series analysis, correlating equipment tag logs with process events to uncover root causes like actuator lag and PLC communication delay—leading to an 8% OEE gain. Led high-impact root cause investigations into frequent torque inconsistency and thermal bond failures using 5-Why analysis, Ishikawa diagrams, and FTA, implemented corrective actions and containment plans that cut rework cycles by 22%. Created prototype drawings and executed 3D printing for concept validation and design refinement. Standardized Process Flow Diagrams (PFDs), Visual Work Instructions (VWIs), Control Plans, and Job Element Sheets (JES) across shifts—reducing new operator onboarding time by 30% and improving procedural compliance. Performed line balancing and time-motion studies using MTM and REFA methodologies; redistributed manual and semiautomated operations to align with takt time, reducing operator idle time by 11%. Led prototype design cycles and performed manufacturing process troubleshooting to validate early-stage builds. Worked closely with quality and production engineers to validate new processes and Product/Process Change Notifications (PCNs). Applied Value Stream Mapping (VSM) to identify bottlenecks and streamline workflows across assembly lines.
EDUCATION
Arizona State University
Master's of Science
Sreenidhi Institute of Science and Technology
Bachelor of Technology - BTech
ABOUT JAYA CHANDRA SEKHAR PONNAPALLI
Manufacturing Engineer with 3+ years of experience in semiconductor and automotive. Improving yield, reducing defects, and optimizing equipment uptime using tools like SPC, DOE, FMEA, and MTM. Skilled in semiconductor process control, cleanroom protocols, and precision manufacturing. Adept at using Minitab, AutoCAD, SCADA systems, and MES platforms to drive data-informed decisions and continuous process improvement. Strong hands-on experience in line balancing, root cause analysis, and quality systemscompliance (ISO/TS 16949
This profile is compiled from publicly available professional sources. Unifers is not affiliated with or endorsed by LinkedIn. Request removal of this profile.