• Technical and Functional lead for new technology engineering automation projects . Core responsibilities: Conceptual design architecture, Proof of concept (R&D), Integrator/Vendor engagement and management.• Design and develop AI based automated solutions for electronic devices assembly and new technology deployments, along with establishing project success path and design for automation.• Champion DOE & DFMA activities for solving New, Unique, Different and Difficult (NUDD) design/manufacturing problems during product development phase for electronic devices.• Technical lead for pack out automation line development. Core responsibilities: Integrator engagement, process flow permutations and proposal development, design packaging for automation.

* Drive engineering projects from concept to implementation working with cross-functional teams in the organization.* Lead a team of engineers and technicians to design, develop, implement and improve all automated assembly equipment and all assembly manufacturing processes.* Perform pre-production process planning for any new product being launched by collaborating with program managers, integrators, and advanced manufacturing teams.* Champion concept & design review meetings with integrators to work on potential DFMA issues from the beginning of the project and collaborate with the plants to drive continuous improvement strategies.* Manage technicians to perform activities related to maintaining/improving equipment like editing robot and PLC/HMI programs, modifying mechanical components through machining and maintaining critical spares for automated equipment.* Lead continuous improvement, corrective actions and FMEA activities in the plant to drive better equipment and labor efficiency across all functions of the plant.

• Managed automation projects with integrators and vendors across 5 different manufacturing plants producing metal, plastic and composite concrete accessory parts through processes like arc and resistance welding, punching, bending, injection molding, laser cutting and pultrusion. • Performed all advanced manufacturing activities for implementing industrial automation and robots for material handling operations. • Collaborated, coordinated and communicated with multiple teams from different plants, vendors and corporate for automation needs assessment in each location . • Designed robot End of Arm Tooling, jigs & fixtures in 3D CAD modeling software and worked with machine and fabrication shops in manufacturing the components using appropriate machining processes at optimized costs. • Researched and developed new technologies like high resolution 2D & 3D measurement systems (Vision system & robotic laser scan systems) for tight tolerance geometric part measurements & defect detection. • Champion concept & design review meetings with integrators, worked on potential DFMA issues from the beginning of the project and collaborate with the plants to drive continuous improvement strategies.

• Designed and Implemented Lean manufacturing cell layouts for various molded automotive interior & exterior components along with performing assembly line balancing for cells with large number of work stations.• Collaborated with program managers and equipment suppliers with preliminary design, design for manufacturability & assembly, manufacturing and launch of automated secondary assembly fixtures.• Developed robot (Fanuc) programs to enable assembly optimization for reduced assembly cycle times in automated robot assembly machines.• Worked on assembly automation design based on sequence of assembly operations and time taken per operation to determine the preliminary fixture design, cost and functions.• Performed component selection and performance optimization for all the mechanical, pneumatic, electronic and controls components based on the assembly operation, product & fixture design and operator ergonomics. • Optimized performance for automated secondary operations like metal clip insertion, welding, riveting, drilling, label application, degating etc based on DOE tryout data after product launch as part of continuous improvement.• Collaborated with supplier programmers in updating & debugging PLC & robot control programs based on assembly requirements and established process verification data.• Programmed and implemented high resolution Vision Systems for defect detection in the automated fixtures along with other detection components like Infra red and laser based proximity sensors. • Performed root cause, 8D & CMM measurement analysis for customer quality alerts and worked with quality engineers in updating FMEA and control plans.• Assisted department managers, technical crew and clients as required with data analysis, scheduling, report generation, project management and warehouse allocations.• Performed data analysis using Microsoft Excel and used CAD for optimizing the plant’s layout.

• Calculated the cycle time for the production process of automotive tubes using time-method study & analysis and reduced the throughput time by eliminating the bottle neck and performed production planning for smooth work flow. • Minimized WIP before the bottleneck station and identified the thickness of the tube as the key characteristic producing variation at cold drawing station and scheduled kaizen events for different departments. • Gained hands on experience with the data analysis, pivot table, VLook up tools, analysis and optimization tools available in Microsoft Excel.