•Implemented Statistical Process Control (SPC) and Failure Mode and Effects Analysis (FMEA), reducing defect rates by 30% and ensuring 98% product compliance with industry standards, minimizing production rework.•Optimized MBOM management within SAP ERP, increasing material tracking accuracy by 20%, reducing material wastage by 15%, and saving $50,000 annually by cutting waste by 500 units/month.•Designed and modeled mechanical components in CATIA and SolidWorks, ensuring ease of manufacturing and reducing production delays by 20%.•Applied Design for Manufacturing (DFM) and Design for Assembly (DFA) techniques, cutting lead times by 15 days and improving product quality across eight product categories, increasing production speed by 12%.•Conducted Finite Element Analysis (FEA) using ANSYS, improving product durability by 15% and stress performance by 18%.•Leveraged Geometric Dimensioning & Tolerancing (GD&T) on 30+ parts, reducing rework and improving production throughput by 10%.•Led Lean Manufacturing initiatives, using Kaizen and Six Sigma to reduce production waste by 18%, enhance productivity by 20%, and reduce cycle time by 15%.•Managed 3D printing projects, reducing development cycles by 25%, improving design accuracy by 30%, and shortening product development timelines by 10%.