SUMMARY
Action oriented process engineer with practical experience in implementing process improvement initiatives in fast paced manufacturing environments.
TECHNICAL COMPETENCIES
Six Sigma- DMAIC, FMEA, PDCA
Lean Manufacturing
Continuous Improvement- 5S, Kaizen, 5 Why, TQM
Time Motion Studies
Statistical Analysis- JMP, Minitab, SAS
CAD Design
Statistical Process Control (SPC)
Value Stream Mapping
Root Cause Analysis- Fishbone, Ishikawa
Product testing- QA audits, ISO, OSHA
ERP/MRP Systems: SAP, MES
MS Word, Excel, Access, Visio
WORK EXPERIENCE
ORGANIZATION 1:
Essentra Filter Products
A leading FDA regulated supplier of non-woven filter products and services primarily catering to tobacco industry.
http://www.essentra.com/filter-products.aspx
DURATION:
September 2012- Present
ROLE& RESPONSIBILITIES:
Manufacturing Specialist
•MANUFACTURING OPERATIONS: Actively monitor the high volume manufacturing cell and assist in troubleshooting technical problems. Supervise operators and support staff to achieve production objectives. Collect, analyze and record process KPIs and tolerances to meet customer requirements.
•PROCESS IMPROVEMENT/IE: Analyze process data to identify bottlenecks and recommend areas with scope for improvement. Drive continuous improvement initiatives by implementing global best practices. Design machine and plant layouts to optimize processes and space. Conduct time motion studies
•QUALITY CONTROL: Conduct periodic testing procedures on semi-finished and finished products to maintain internal and external standards. Monitor critical product parameters in real-time using Statistical Process Control (SPC) and eliminate variances. Facilitate in new product trials to meet customer requirements.
ACHIEVEMENTS
•Completed Six Sigma Project to reduce the process variation in high margin manufacturing process which yielded estimated savings of more than $100,000 per year.
•Reduced process rejects by 10% by creating an efficient product auditing system for QC personnel.
•Helped reduce overall plant waste by 2% through various awareness initiatives and rigorous tracking.
•Identified the key causes for high cost variance created due to raw material utilization in different manufacturing processes. My recommendations resulted in variance reduction of 3% in three months.
•Created proposal drawings to redesign the existing plant layout in order to incorporate new equipment purchases, and streamline existing manufacturing cells to improve efficiency and quality.
•Facilitated in reducing unplanned downtime in new high volume manufacturing process by 12%
•Created a systematic plant head count planner based on process capabilities and production forecasts.
ORGANIZATION 2:
Contract Packaging Resources, Inc.
A leading cGMP compliant and FDA, DEA regulated service provider to the pharmaceutical industry specializing in RX/OTC bottling, blister packaging, etc.
www.cprwebsite.com
DURATION: June-December 2011
ROLE & RESPONSIBILITIES: Industrial Engineering Intern
•Observe and validate the efficiency of product changeover processes in manufacturing lines and identify the causes for downtime.
•Analyze the effectiveness of sensors in packaging detection process and reduce product rejection rate.
•To streamline the production process based on the collected data.
ACHIEVEMENTS:
•Initiated Six Sigma...
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