Harshit Soni Email & Phone Number

California, United States

Fremont, California, United States

• Lead process engineering for battery packaging zone, spearheading innovation across 15+ steps to enhance yield and throughput, driving critical projects that ensure timely shipments and operational excellence.• Direct a team of 3 Process Engineers and 3 Technicians in coordinating and executing new product processing setup and release, optimizing manufacturing sub-processes for seamless production integration.• Successfully led a project to develop a process that increased a key… Show more • Lead process engineering for battery packaging zone, spearheading innovation across 15+ steps to enhance yield and throughput, driving critical projects that ensure timely shipments and operational excellence.• Direct a team of 3 Process Engineers and 3 Technicians in coordinating and executing new product processing setup and release, optimizing manufacturing sub-processes for seamless production integration.• Successfully led a project to develop a process that increased a key process output Cpk from 0.8 to 3.6 (350% increase) thereby enabling the company to position our product as a standout offering, enhancing our competitive edge.• Championed the elimination of a critical low-detection defect through robust process development, reducing the RPN from 224 to 36 while ensuring compliance with stringent customer tests and maintaining product quality integrity.• Key contributor to innovative manufacturing process development, optimizing high-volume production, reducing Capex, and eliminating critical defects all across product types. Inventor in 2 patent filings, demonstrating advanced problem-solving in manufacturability and quality improvement.• Spearhead overseas collaboration within the company to release the next-gen production line by conducting proof-of-concept (POC) studies to assess Design for Manufacturing (DFM) risks and the impact on product quality.• Evaluated new product designs for manufacturing risks and led R&D builds to ensure quality and safety, successfully communicating results to executives and implementing action plans that facilitated a smooth transition to mass production. Show less

Fremont, California, United States

• Managed scale-up of multiple battery manufacturing processes by conducting Design of experiments (DOE) for process development, locking process recipes, increasing tool UPH, and improving process robustness. • Achieved ~50% increase in OEE by communicating tool issues with different teams (Controls/Equipment/Mechanical), brainstorming ideas, and implementing action plans to improve equipment availability. • Contributed towards company shipment goals by achieving a 72% increase in… Show more • Managed scale-up of multiple battery manufacturing processes by conducting Design of experiments (DOE) for process development, locking process recipes, increasing tool UPH, and improving process robustness. • Achieved ~50% increase in OEE by communicating tool issues with different teams (Controls/Equipment/Mechanical), brainstorming ideas, and implementing action plans to improve equipment availability. • Contributed towards company shipment goals by achieving a 72% increase in process UPH while maintaining a yield of >99%. • Developed 40+ interactive automated scripts using Python, R, and SQL to reduce data extraction and analysis time by up to 99%. • Successfully passed a POC study by achieving a ~79% higher process window with the current manual process to enable high volume manufacturing using automated Gen2 tools. • Achieved 11% GR&R down from 45% by modifying existing test equipment thereby enabling frequent testing to ensure product quality is maintained. • Developed and deployed SPC monitoring, WIs, and Out of Control Action Plans (OCAPs) for operators and techs to react quicker to defects and prevent yield excursions. • Optimized Trumpf pulse laser pattern and parameters to significantly lower laser weld debris while achieving a weld strength Ppk of 1.5 (47% increase). • Communicated with various suppliers to redesign incoming material patterns and heavily poke-yoked a manual process thereby preventing yield excursions and lowering RPN of 15 failure modes below the critical threshold. • Contributed to the design of next-gen high-volume manufacturing line based on the challenges from the current-gen line, completing Proof-of-Concept (POC) studies, and targeting the fundamental design of the product for improved DFx. Show less

Fremont, California, United States

• Supported critical pilot line production by developing & improving processes, monitoring yield, and implementing action plans to improve overall yield and OEE.• Re-designed fixtures using Solidworks to significantly reduce a major defect from 25% to 1% along with reducing the false-fail errors.• Effectively used GR&R to assess the variation in the measurement system while implementing a new fixture on the production line. • Communicated with vendors regarding the material… Show more • Supported critical pilot line production by developing & improving processes, monitoring yield, and implementing action plans to improve overall yield and OEE.• Re-designed fixtures using Solidworks to significantly reduce a major defect from 25% to 1% along with reducing the false-fail errors.• Effectively used GR&R to assess the variation in the measurement system while implementing a new fixture on the production line. • Communicated with vendors regarding the material requirements and the fabrication of the fixtures.• Performed real-time SPC monitoring using automated scripts written in SQL, R & Python to monitor the quality of the product and drive continuous improvement to reduce the non-conforming parts. • Communicated with engineering techs, production supervisors, team leaders and production associates regarding any change in a process, preventive and autonomous maintenance, and training required for all the shifts regarding a new process.• Designed a glue catch tray to prevent the glue from contaminating the part by re-directing the glue flow away from the main part and making the catch tray swappable to drastically reduce the time taken to change the catch tray.• Developed a process to check for defects in a part before being used for production in order to reject the parts beforehand rather than later down the line keeping in mind the productive and non-productive time in the process. Show less

Danvers, Ma

• Supported process improvement projects (adhering to FDA’s CGMP regulations) by effectively utilizing Lean and Six Sigma tools for analyzing the process trend data.• Used data driven approach to find correlations between factors & defects and identified opportunities for yield improvement.• Conducted IQ and OQ on various equipment using metrology tools and equipment such as Keyence digital microscope, Micro-Vu, and techniques such as GR&R and Ppk while adhering to FDA’s GMP… Show more • Supported process improvement projects (adhering to FDA’s CGMP regulations) by effectively utilizing Lean and Six Sigma tools for analyzing the process trend data.• Used data driven approach to find correlations between factors & defects and identified opportunities for yield improvement.• Conducted IQ and OQ on various equipment using metrology tools and equipment such as Keyence digital microscope, Micro-Vu, and techniques such as GR&R and Ppk while adhering to FDA’s GMP regulations.• Conceptualized and designed a fixture using Solidworks to combine 2 processes, ultimately reducing overall process time by 20% along with introducing process standardization and poka-yoking.• Recognized for solving a problem of a tight fit between two components across two manufacturing plants by developing action plans after thorough process investigation and DOE analysis using Minitab. Show less

Sanand, Gujarat, India

• Spearheaded day-to-day functionality in an internship role, thereby developing fundamental skills in the field. • Successfully devised and implemented action plans after a thorough investigation of pallet damages. Slashed the pallet damages by ~60% while saving $50K per year and strengthening operator efficiency by ~20%• Inspected over 2000 pallets to identify patterns among the pallet damages and suggested action plans accordingly.• Communicated with the line operators and team… Show more • Spearheaded day-to-day functionality in an internship role, thereby developing fundamental skills in the field. • Successfully devised and implemented action plans after a thorough investigation of pallet damages. Slashed the pallet damages by ~60% while saving $50K per year and strengthening operator efficiency by ~20%• Inspected over 2000 pallets to identify patterns among the pallet damages and suggested action plans accordingly.• Communicated with the line operators and team leaders to get detailed information regarding the process followed to stack up empty pallets.• Used six sigma tools such as Time Studies, Cause & Effect Diagram and 5 Whys to find the root cause of the damages. Show less

Master Of Science - Ms, Manufacturing & Mechanical Systems Integration

Bachelor Of Technology - Btech, Mechanical Engineering