Manufacturing Engineer - Continuous Improvement
Ducab
مجموع سنوات الخبرة :15 years, 9 أشهر
Role & Responsibilities:
• Lead product and process establishment in the plant for new projects.
Rubber and Nuclear Cables - AED 100 m project.
• Lead tendering process, installation and commissioning of machines for new projects.
• Formulate strategy & deployment of Lean Principles within organization.
• Train, develop and drive employees for using tools of Lean Six Sigma, 5S and TPM.
Achievements:
• Led the cost saving project for flexible conductors (new product), and thereby contributing to savings of over AED 1 M.
• Increased the productivity of machines to debottleneck the process by driving autonomous maintenance, quick changeover, workplace organization and visual management for key machines.
• Implemented SAP Warehouse Management (WM) for better Inventory Control and thereby reducing the WIP in the plant by 30%.
• Develop management systems for new processes, by establishing the process and machine specification to align with Ducab QHSE system.
Role & Responsibilities:
• Drive Operational Excellence (OpEx) in 3 diversified verticals of Engineering (PMP Auto Comp),
Textiles (Morarjee Textiles Limited) and Real Estate (Peninsula Land Limited)
• Develop Corporate Strategy for Lean Six-Sigma (LSS), Training Program and OpEx Deployment
• Lead Culture Change by engaging shop-floor employees in 5S, Quality Circles, Problem
Solving Methodologies, Kaizen Events and Machine Ownership Program
Achievements:
• Facilitated 14 LSS Projects across group companies in alignment with their BSC to directly have a
net impact of Rs 2.4 crores
• Implemented end-to-end PMS cycle with HR Team to align the KPI of over 2000 employees with
the Balanced Score Card of the corporate group with individual businesses.
• Accomplished B Rating in Volkswagen AG Supplier Audit with 87% score in PMP Auto
• Initiated Capability Building across group companies by identifying and training 20 candidates for
LSS Green Belt Certification from Quality Council of Indiana - Qimpro consultancy
• Delivered Training in OpEx modules for 250 mandays for functional implementation of LSS
Role & Responsibilities:
• Led Continuous Improvement Process across Locations - 3 manufacturing facilities
• Responsible for Lean Implementation of Workplace Organization, Inventory Management, Total
Productive Maintenance (TPM) and DMAIC - Six-Sigma projects
• Conducted Training Sessions on Lean Manufacturing Modules to all company employees
Achievements:
• Led 4 DMAIC Projects in production and quality, resulting in savings of Rs 2.5 crores
• Restructured the inventory management by developing Just in Time (JIT) - Pull Process and thereby reduced Work-in-Process from 4 days to 1.5 days
• Implemented Total Productive Maintenance (TPM) on high speed manufacturing process to increase its Overall Equipment Effectiveness (OEE) from 70% to 85%
• Led Location wide 5S Program by training, zone structuring, weekly audits, and assigning corrective actions for continual improvement to reach 4th S Level - Standardize
Role & Responsibilities:
• Manage the Cost, Productivity, Quality and Safety (CPQS) in Paint and Sheet Metal Department
• Assist Continuous Improvement activities in Welding Department
• Core Team Member of Quality Control and Lean Department for project work
Achievements:
• Led the Analysis of Scrap Reduction Project in Sheet Metal Department to highlight the potential
savings of $ 1 million by conducting Root Cause Analysis
• Developed Cost of Poor Quality (COPQ ) Metrics using MS Excel Macros for paint department thus highlighting the scope of saving $ 0.6 million per year
• Initiated Six-Sigma Project for Auto-Packaging System by following the DMAIC and CEDAC process to improve quality rate from 84% from 99.2%
• Increased productivity in welding department by using lean tools like Kanban sizing,
• Cellular Manufacturing &Single-piece flow, from 40 parts/hour to 56 parts/hour
Role & Responsibilities:
• Project - Development of Mini-Laser Deposition system with Micro Wire-Feeder to improve material efficiency up to 90% and reduce the cost by 75% compared to current technology to target small-scale industries
• Research supported by National Science Foundation grants DMI - 9871185 and IIP - 0637796,
guided under Dr. Frank Liou and Dr. James Newkirk
• Use Advanced Statistical Tools to measure, analyze and make the system robust
Achievements:
• Designed, developed and optimized a micro-wire feeder to handle metallic wires of sizes
as low as 100 microns to facilitate laser metal deposition/welding
• Developed a Working Model with 97% reliability and 95 % precision
• Published Research Papers in ASME - American Society of Mechanical Engineers and Missouri University and Science & Technology
Role & Responsibilities:
• Scheduling and Supervising production in Fabrication & Paint Department
• Manage Part co-ordination and Inventory Count for Dyna & XL Lean Assembly Lines
• Cross-functional Team Member in Operational Excellence Department
Achievements:
• Improved the quality of powder coat process by using Statistical Process Control(SPC) and Taguchi’s Orthogonal Array to increase the first pass yield from 92% to 97%
• Initiated 5S in paint department to reduce spare part cost, thus saving $ 50000 per year
• Developed Visual Aid Management tools for smooth production of 2010 Model Year Launch
• Conducted Job Safety Analysis to achieve the yearly target of 10% reduction in ergonomic score