Girish Byrappa Email & Phone Number

Racine, Wi, Us

Sturtevant, Wisconsin, Us

I assumed the role of Quality Control Manager in 2015. I oversee cross-functional teams and manage multi-million dollar budget to streamline quality control operations and meet time bound objectives. I was appreciated by management for sourcing components and castings from international suppliers while reducing costs and ensuring strict adherence to specified quality standards. I was responsible for analyzing market orientations to re-negotiate prices for service parts with OEMs and identify opportunities. I automate processes and systems to adjust engagement with suppliers and monitor EDI coming through/from OEM customers.• Resourced Castings from a troubled supplier in Canada to 3 suppliers in the US in 8 weeks resulting in the reduction of quality and freight cost reductions by over $1.2M per year.• Reduced cost of a load limiter sleeve by $0.04/unit by changing design, resulting in $260,000 savings on a 6.5M Units/yr program.• Launched fuel pump bracket on the Ford 2.7L Eco boost engine after the prototype die-cast part failed crash testing. New part was re-designed as a forging and supplier was selected overseas, audited and tooled up in 12 weeks for the 2020 model year F-250 pick-up trucks with volume in excess of 275, 000 parts per year.

I was appointed as Quality Engineer in 2011 and I launched automated feedback of daily scrap rates for all major suppliers through the ERP system to commence troubleshooting and inspect errors. Also, I collaborated with suppliers to select appropriate parameters and decrease casting defects. Inspected materials and processes to determine corrective actions and implement quality control measures. My duties involved monitoring daily operations to ensure workflows, processes, and products comply with safety regulations.• Coordinated with Tier 2 suppliers in setting up DOE's for casting parameters (die temperature, fast shot, slow shot etc) to reduce gas and shrink porosity on A380 castings. Reduced overall scrap percentage from 15% to less than 1.5% in 8 weeks.• Developed Supplier Scorecards for all CTQ suppliers including Ongoing PPM, Delivery, 8D's and supplier audit scores.• Commenced data driven tool life management on all critical features by training operators on Xbar and R charts and Cpk/Ppk training.

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