Aniesh Sampathkumar Email & Phone Number

Livonia, Michigan, United States

Livonia, Michigan, United States

Warren, Michigan, United States

- Rebalanced stations for Vehicle Assembly (GA), Paint, and Body-in-White (BIW), impacting manpower allocation and reducing non-value-added activities (NVAA).- Initiated human posture studies and analyzed CAD data to eliminate MURI conditions, improving ergonomics.- Recorded, tracked, and resolved multiple issues through the RMS database, leading to improved processes.- Conducted root cause analysis (RCA) on quality issues, drove PFMEA activities, and supported Quality Verification Stations (QVS).- Saved over $2 million through Kaizen activities by reducing NVAA, optimizing manpower and tools, and lowering PFMEA Risk Priority Numbers (RPN).- Developed station scrolls for GA, BIW, and Paint, performed MODAPTS analysis to evaluate VA/NVA activities, and reduced waste.- Utilized AutoCAD to modify the layout of manned stations by validating stock locations and optimizing station setups for better floor utilization.- Supported World Class Manufacturing (WCM) initiatives, focusing on Workplace Organization (WO) and Logistics (LO) pillars.- Conducted multiple time studies to evaluate conveyors, robots, and stations, and reported findings in a weekly chart.- Collaborated with Product, Tooling, Quality, MLM, and Launch teams for through Launch Loop activities.

Greater Detroit Area

- Interact with customers, visit their manufacturing units, and resolve quality issues.- Lead FRB meetings to address open internal and external quality concerns for all programs.- Initiate and organize 8D meetings and contribute to containment actions, verification, and validation of PCA.- Conduct root cause analysis and implement corrective and preventive actions for deviations.- Collaborate with the customer STA to close any gaps in current processes and ensure customer satisfaction.- Conduct Gage R&R studies to maintain inspection standards.- Analyze daily CMM reports to monitor part specifications and make corrections when deviations are identified.- Develop and implement continuous training plans for inspectors and conduct periodic training activities.- Monitor the Control Plan and verify that all check methods are properly implemented on the floor.- Tabulate and maintain NCRs daily and use them to populate iCharts and trend charts every month.- Prepare Line Inspection Reports for machine moves, new fixtures, new tools, and other requirements.- Instruct and oversee the Material Review Board and analyze suspect data collected.- Organize and assign tasks to quality inspectors based on daily customer requirements.- Maintain 5S standards on the shop floor.- Prepare quality alerts for customer complaints and train inspectors accordingly.- Update Work Instructions, PFMEAs, and Control Plans for in-process inspection controls and final inspections as needed.- Participate in layered process audits to assess current scenarios and suggest improvements to existing processes.- Prepare a monthly scrap data report to track scrap rates and identify the top 6 issues for parts produced through Pareto analysis.

Coimbatore Area, India

- Identified and eliminated bottlenecks using the Theory of Constraints, improving throughput.- Maintained raw, WIP, and finished products in accordance with Just-In-Time principles to free up floor space and improve efficiency.- Conducted cycle time studies to eliminate waste and perform line balancing, enhancing station efficiency.- Analyzed OEE data and reduced downtime by scheduling preventive maintenance (PM) and servicing maintenance (SM), minimizing time wastage.- Performed MODAPTS analysis on existing Standard Operating Procedures (SOPs) to identify areas for improvement, thereby rebalancing the workforce for maximum efficiency.- Reported weekly and monthly KPIs, compared them against benchmark standards, and conducted root cause analysis to improve productivity.- Analyzed manpower utilization weekly and planned schedules to optimize the workforce, reducing costs.- Conducted continuous improvement activities, implementing lean techniques to minimize scrap and enhance efficiency.- Established procedures for incoming inspections and online inspections.- Calibrated and maintained inspection equipment using Gage R&R methods.- Implemented 5S on the shop floor.- Participated in NCR investigation teams and engaged in 5-why analysis for corrective and preventive actions (CAPA).- Updated PPAP documents in accordance with closed quality concerns and institutionalized lessons learned.- Conducted audits on SOPs and work instructions (WIs) and made necessary changes.

Master Of Science (M.S.), Industrial Engineering

Graduate Research Assistant – RAID Labs August 2013 – May 2014 • Analyzed various statistical data collected from experiments in Six Sigma.

Bachelor Of Engineering - Be, Mechanical Engineering