Value Stream Lead at Samuel-ATC (2024-03 – Present)
Leader in manufacturing stainless steel tubes for aerospace, military, air-conditioning, & automotive industries
- Developed and standardized a system for managing improvement projects
- Developed VSMs via team meetings
- Participated in KPI development for various operations/ departments
- Developed a method for time study and operations standardization for MTO and batch manufacturing
- Implemented 'Day-by-Hour' sheets for various machines/ processes
- Participated in developing TIB boards for various departments and value streams
- Conducted human/ machine operation studies which resulted to work standardization and improvement projects
- Conducted all above according to Lean Management principles and methodologies
- Designed new production lines & improved existing lines
- Selected contractors and managed projects of production line deployment
Project Engineer at Silfab Solar (2021-03 – 2024-03)
A leading manufacturer of solar panels in North America
- Responsible for expansion/ upgrade and improvement projects
- Developing project plan, budget estimation, and cost control
- Ordering special process equipment and working with supplier equipment development
- Coordinated project shareholders: OEMs, installers, and internal departments
- Responsible for developing plant layout for fully automated lines
- Responsible for preparing RFQ for equipment vendors & coordinated for shipping & delivery
- Responsible for PHSR, commissioning and trial runs
CORPORATE ASSEMBLY PROCESS PLANNING ENGINEER at Kirchhoff Automotive (NA head office) (2017-01 – 2020-02)
A main German tier1 manufacturer of automotive body parts with plants in Europe, NA, and Asia. The main products are cross-car-beam, various body and chassis assemblies
- Developed manufacturing process for all the Kirchhoff's NA plants based on one-piece-flow
- Developed VSM for current and future states
- Designed processes for assemblies supplied to various OEMs such as Honda, Volvo, Daimler, BMW, Ford, GM, FCA
- Developed build sequence, manufacturing processes, CT chart for new products from various OEMs
- Developed complete manufacturing process including robotic spot/ GMAW/ projection/ drawn arc welding, riveting, clinching, periphery equipment
- Developed tooling/clamping concept for welding/ assembly based on build sequence & GD&T
- Developed manual assembly sequence and calculated operation time using BasicMOST
- In response to RFQs, dealt with vendors and developed estimation and quote for tooling, main and periphery equipment
- Reviewed and validated processes originally designed by various integrators
- Reviewed, improved/ optimized existing processes and layouts based on VSM methodology
SENIOR PROJECT ENGINEER (Program Management) at ABC Group (2015-01 – 2016-12)
A main tier1 Canadian designer & manufacturer of automotive plastic parts
- Managed product development projects from design to PPAP submission
- Visited OEM plants and participated in joined review meetings
- Conducted milk-run logistic planning
- Conducted product development in various stages: design, DFMEA, DVP&R, mold design, prototype build, trials, problem resolution, customer specific requirements, AAR
- Conducted GD&T stack up analysis, gage design and build activities
- Component supplier selection, audited supplier processes, PPAP documentation, gage build
- Conducted product design and material improvement activities
- Exposed to injection molding process of plastic and rubber
QUALITY/ PROCESS ENGINEER at Multimatic Manufacturing (2010-10 – 2014-12)
A main tier1 Canadian designer & manufacturer of hinge systems, door Checkers, Flex-steps
- Participated in new product development projects for Toyota, BMW, GM and Nissan
- Improved and resolved process/ quality/ measurement issues
- Designed / improved tooling and gages for various manufacturing processes
- Conducted process audit, problem recreation study, Kaizen projects, and FTA analysis
- Developed & updated control plan, PFMEA, technical reports, and customer specific documents
- Resolved customer concerns by root cause analysis, implementing temporary & permanent countermeasures, and visiting customer premises
- Prepared product validation and material test reports
- Prepared documentation for various stages of APQP process, prototype build and PPAP
- Analyzed assembly and components dimensions and tolerance stack-up
- Visited suppliers to resolve quality and technical issues
- Exposed to stamping, progressive dies, staking, riveting, automated & robotic assembly processes
PROCESS ENGINEER/ PROGRAM MANAGER at Arvin Meritor (2006-06 – 2008-12)
A tier one manufacturer of Exhaust Systems with numerous facilities across NA; The Concord plant was shut down
- Responsible for new product / process development projects for GM and Toyota products
- Designed new production lines based on Lean Manufacturing principles
- Prepared quotation and cost estimations for new projects
- Sourced and ordered equipment, tooling, gages, material handling and secondary equipment
- Conducted prototype build, process capability, GR&R, and run@rate
- Conducted Kaizen projects to improve safety/ quality / productivity/ ergonomics issues
- Conducted VSM session to plan improvements (to reduce wastes and create flow)
- Implemented balanced One-Piece-Flow manufacturing cells, and various Poka-Yokes
- Developed APQP documents, setup instruction, and standard operation sheet
- Exposed to bending, cutting, sizing, stamping, and various methods of automatic welding
PROJECT / INDUSTRIAL ENGINEER at MAGNA Powertrain- Unimotion Gear (2003-12 – 2006-04)
A tier one company that produces Flexplate and Balancer Shaft; and GM, Daimler-Chrysler, Ford, Mazda, Nissan, Honda, Porsche, and Jaguar were among its main customers
- Designed layout for new production lines
- Participated in OEE improvement and QDC (Quick Die Change) activities and related projects
- Sourced line automation, material handling, production tooling, gages and secondary equipment
- Developed 3D models and process drawings (using SolidWorks)
- Designed tools for improving manufacturing operations
- Participated in new product development projects
- Developed PPAP documentations (BOM, PFD, DFMEA, PFMEA, operator instruction, etc.)
- Conducted prototype build, capability analysis and GR&R
- Supported suppliers by providing technical information and assistance
- Exposed to stamping, heat treatment, roll forming, CNC machining, MIG welding, robotic assembly
