Md Faisal Bin Shaikat Email & Phone Number

United States

Weirton, West Virginia, United States

• Contract-based job From Goken America
• Designed industrial plant layouts for facilities ranging from 12.5 MW to 500 MW, optimizing 815K square feet of space. Considered key factors such as construction cost, process flow, material flow, warehouse layout.
• Conducted comprehensive CapEx and OpEx analyses for industrial facilities, focusing on factory-wide capital expenditures and operational costs related to material flow and staging.
• Optimized automated injection molding operations using 6 ENGEL machines. Designed layouts for drawing, loading/unloading areas, robot placement, and overhead conveyor delivery systems to streamline ring vessel.
• Developed comprehensive product specifications and design documentation for battery systems, including anode, cathode, cell, module, and enclosure components. Collaborated with cross-functional teams to define business.
• Successfully implemented Lean manufacturing principles, driving a 22% improvement in cost through initiatives such as continuous improvement, 5S, and OEE.

Dhaka, Bangladesh

• Successfully Achieved a 27% reduction in defects and eliminated root causes of defects using Six Sigma tools, implemented Poka-Yoke devices to prevent errors, and fostered a culture of continuous improvement through.
• Led the successful implementation of a Kanban system, resulting in an 11.7% increase in throughput and a 13.3% reduction in inventory by eliminating waste and optimizing production flow.
• Optimized apparel industry simulations and product design using Catia and SolidWorks, leading to a 7.732% reduction in development time and a 22.27% improvement in product quality.
• Experienced in applying MOST techniques to analyze and improve manufacturing operations, driving efficiency and cost savings.
• Successfully resolved warehouse capacity issues by utilizing FlexSim to simulate various scenarios and identify the most efficient layout and equipment configurations.
• Leveraged FMEA and PFMEA to identify potential failure modes in machines and processes, taking immediate action when RPN exceeded 100 to prevent adverse outcomes.

Dhaka, Bangladesh

• Oversaw comprehensive FAT and SAT testing to validate equipment performance and alignment with specifications for different types of Laser machines.
• Optimized inventory level of 1000+ SKUs using ABC segmentation analysis that reduced cycle stock by 31% and cost by $50K+ also increased inventory turnover.
• Implement the 5S Lean method that increased warehouse capacity utilization by 28% and reduced waste by 42%.
• Meticulously documented dimensional data using Vernier Calipers, Height Gauges, and Tape Measures by reading blueprints containing GD&T and creating comprehensive Part Submission Warrants (PSW).
• Achieved 100% success rate in implementing engineering changes, with extensive experience in MIG welding and component assembly. Proficient in interpreting drawings and applying welding metallurgy principles.
• Conduct time studies, motion studies, work sampling, and quarterly projects with teams of mechanical and tooling engineers. Lead workshops and Gemba walks for 10+ people, including research for new $75K A-Frames after.

Dhaka, Bangladesh

• Achieved a significant reduction in inventory defects by 2% per 1000 pieces through effective DMAIC implementation
• Streamlined operations through the development of new work instructions and manufacturing layouts using AutoCAD
• Leader of the KPO team for the improvement of productive processes, EHS, and quality.
• Consistently maintained scrap rates below 14.27% during ramp-up and post-SOP, ensuring optimal product quality and efficiency
• Worked with site leadership to set targets and projected costs for continuous improvement projects used to meet annual site goals for First Time Right, WCM savings, On Time Delivery (OTIF), and labor efficiency metrics.
• Conducted rigorous ROI analyses to support capital investment proposals, ensuring strategic allocation of resources

Master'S Degree, Industrial Engineering

Smart Manufacturing (Professional Certification )

Textile Sciences And Engineering