-Creating and updating VSM’s, Process Flow and Capacity Charts for all fabrication processes.-Implementing and monitoring Overall Equipment Implementation "O.E.E " and "Downtime" calculation metric sheets in multiple areas-Facilitating in the implementation of a Pull System( P-KANBAN) throughout fabrication and Standardized Footprints throughout the fabrication VSM-Implementing production planning and scheduling for bottleneck processes-Conducting multiple 3 day Accelerated Improvement workshops"AIW" for improvements in flow through bottle neck area -Creating standardized procedures ,Standard Operating Instructions (SOI), Standard Work Combination Sheets (SWCS), Standard Work In-Progress (SWIP) in different areas in fabrication-Facilitating in Root Cause & Corrective Action(RCCA) and 8-Step problem solving teams for problematic areas-Creating and Updating Capacity and Level Loading charts for all areas in fabrication-Conducting line balancing(VA-NVA), cycle time reduction( Red-Green Observation Sheet), time & motion and ergonomic studies for bottle neck processes -Conducting workshops for layout,flow and changeover optimization in fabrication.-Conducting workshops for labour and machine optimization with increased rate with minimum layout changes

-Worked as a Project manager for the line setup/alteration for LPI Intake Air Fuel Module (IAFM) in plastics from scheduling, cost estimating, specifying & sourcing all equipment to pilot builds and getting production readiness at the required customer rate.-Worked with the sub contractors from the design to final build for multiple jigs, POKA-YOKE fixtures and gauges for quality control and ease of operations.-Conducted multiple cost estimations for new projects and created in house production feasibility reports for different stakeholders -Commissioned Fanuc paint robot in paint shop ( Zone 1,Class 1 area) and transferred multiple manual paint jobs to robot painting thus saving the company $35,000/annum -Improved die change over time by S.M.E.D analysis (Single Minute Exchange of Dies) for 108 Dies. Standardized the processes from internal to external and reduced the die change over time from 45mins to 30mins thus saving the company 3300 mins per annum of production time.-Setup and successfully implemented T-KANBAN between Plastics, warehouse and assembly departments. eliminated 70% inventory, reduced storage space, packaging and energy costs -Successfully submitted 54 PPAP’s for 4 major customers (Ford, Holden, Toyota & BMW) and multiple internal submissions-Conducted multiple Die trials, capability, Gauge R&R studies for numerous parts for PPAP submissions and ongoing production changes.-Created and improved numerous SOP’s quality through pictorial, visual and better readability for the operators to better understanding of the processes and controlling rejects.-Modified and made new PFD’s, PFMEA and CP’s for plastics, paint shop and coating room for multiple parts.-Trained die setters and operators of 5S, proper line balancing, cycle time reduction , process flow optimization and work standardization-Creating and updating all the Build Of Material “ BOM” for all the parts and updating the MRP system(SAP) on regular basis for production scheduling

-Worked with 4 sheet metal suppliers for end-to-end Product Development life cycle(PLC), including concept, drawings, prototypes, testing, finalizing and manufacturing roll out.-Hands on experience of preparation and validation of prototypes and off tool samples (TO) for assembly line try outs.-Conducted Design of testing experiments including the construction of for parts and jigs .Also conducted DFMEA & PFMEA with suppliers for all out sourced parts -Conducted monthly SQAM audits and improved supplier awareness towards in-process quality gates and final inspection methods. Prepared comprehensive audit reports high lightening the weak areas and re-auditing for successful permanent countermeasure implementations. -Documentation preparation including drawings ,bills of material, work instructions and technical specifications for out-sourced parts -Trained suppliers to improve proper PPE’s and STOP 6 action implementation-Implemented and improved all quality control systems (PIS, PLC,PFC, MQC, PFMEA) for their defect free production and shipment-Reduced the overall line side DPU (Defects per Unit) contribution of local parts from 1.7 % to 0.5 % for 2009 by working with the problematic suppliers/parts by implementing POKA-YOKE technology at suppliers. -Worked closely with Quality Receiving department for the inspection of incoming parts, verifying the CF’s, inspecting the part quality reports and communicating with supplier for improvements in parts, dies. Inspection gauges and CF’s. Improved overall quality by 55%-Facilitated, Lead & Implemented S.M.E.D (Single Minute Exchange of Dies) with 2 suppliers -Improved process flow of 3 Tandem lines. Reduced scrap by 50% at 3 suppliers