Sandeep Ravi Kumar Email & Phone Number

Glen Rock, New Jersey, United States

United States

- Developed VBA tool for efficient stock replenishment in the distribution center (DC), USA & Canada.- Spearheaded continuous improvement projects worth $400,000 USD with an ROI of 3.5 years.- Redesigned facility layout to establish a streamlined kaizen flow, eliminating bottlenecks.- Improved material handling efficiency by streamlining pick strategy leading to a 15% increase in picking efficiency.- Developed a quantitative model for efficient labor planning through demand forecast based on historical trend.- Improved DC space utilization by consolidating non-moving inventory through ABCD and Aging SKU analysis.- Conducted time motions studies and established engineered labor standards.- Developed performance metrics, and dashboards to assist management with data driven business decisions.- Provided recommendations by benchmarking DC operations against other comparable organizations.

United States

- Developed interactive KPI dashboards with excel macros, automated data extractions for dashboards.- Forecasted customer demand based on historical outbound data and assisted with efficient labor planning.- Redesigned facility layout using AutoCAD and established a Kaizen flow achieving improved capacity.- Designed and developed visualizations, reports and metrics to assist with critical business decisions.- Created SQL queries to generate warehouse reports tracking inventory and shipment data.- Conducted time motions studies and established engineered labor standards.- Analyzed value added services and created pricing quotes based on labor standards.- Developed standard operating procedures for warehouse operations.

South Plainfield, New Jersey, United States

− Drafted standard operating procedures for manufacturing support systems in accordance with GXP Regulations.− Utilized risk analysis methodology, to identify and eliminate potential failure modes in manufacturing systems.− Extracted datasets using queries, established trends, and reports to analyze validation data.− Trained and assisted with laboratory system installation, and its HVAC system.

Ames, Iowa, United States

- Trained students on CAD programs for 2D & 3D modeling, measurement tools, and manufacturing equipment/processes.- Trained students on lean initiatives such as Kaizen, 5S, Takt time analysis, QFD, and Poka-Yokes.- Assist students with questions concerning labs to help them fully understand the procedures.- Enforce best practices in the lab to promote safety, precision, accuracy, and problem-solving.

Ames, Iowa, United States

- Utilized deep UV & IR laser to ablate micro holes/grooves of 20μm resolution on polymers films. - Characterized the laser to obtain smooth features with little to no debris redeposition. - Utilized Minitab control charts to achieve process stability and identify process outliers.- Formulated quantitative models to accurately predict the dimensions of the micro-features fabricated.

Grundy Center, Iowa

Richelieu Foods at Grundy Center, Iowa, manufacture bottled sauces, salad dressings, and marinades for Walmart, Aldi, Kikkoman, and Hyvee.- Conducted (MOST) cycle time analysis on 40 SKUs in the mixing room and established labor standards & workforce optimization. Utilized cycle time data and simulated production floor to identify speed bottlenecks, thereby eliminating idle times, and achieved line balance.- Established a preventive maintenance system on every asset of the plant, using ManagerPlus (CMMS). Created standard work instructions for the maintenance activities on every asset. This resulted in increased throughput, machine efficiency, product quality, and downtime costs.- Performed root cause analysis using fishbone diagrams, Pareto charts, scatter plots, 5-whys, and statistical analysis for equipment breakdowns and quality issues. Developed and coordinated containment actions, corrective and preventive action implementation. - Developed and evaluated Key Performance Indicators (KPI) like RTY, Scrap, OEE, and Labor efficiency to track performance.- Participated in daily Gemba walks. Identified and eliminated ergonomics, and safety issues in the plant to ensure a zero-accident environment.- Assisted with performing feasibility studies, cost analysis (ROI) for new projects, and daily production-yield analysis.

Chennai, Tamil Nadu, India

Phorotech Surfin provides engineering services such as liquid coating, powder coating, and Geomet coating services for Hyundai Motor's car door frame parts and other automotive OEMs. - Created value stream maps for 4 process lines and identified NVA. Headed 4 kaizen events and a six-sigma green belt project to completion and attained a 14% improvement in workflow efficiency. - Validated process changes in the electrocoating and Geomet coating process lines, by conducting capability studies, stability analysis using Minitab. Implemented Poka-Yoke methods to eliminate out of control variances and increased CpK >1.33. - Organized the workplace using the 5S methodology with continual audits and reinforcements. Worked hands-on installation of shadow boards, visual instructions, procedure labels, etc. Achieved a 30% increase in workspace availability. - Developed a simulation model using Simio to optimize plant operations including manpower allocation and bottleneck elimination. - Utilized RCA tools such as Pareto charts, Ishikawa diagrams, Scatter plots, 5-whys, etc. to address customer non-conformances and unplanned downtime contributors. Successfully coordinated the implementation of corrective and preventive actions. - Built real-time visualizations and weekly KPI dashboards to track performance that helped the management make data-driven decisions. Used Excel, VBA, SQL, and Power BI for data analysis. - Conducted ANOVA, t-test, regression analysis to address root causes of production & quality issues. - Headed cross-functional kaizen teams and successfully drove 4 kaizen events to completion. I acted as the facilitator. I was responsible for planning & scheduling the entire kaizen event, training the team on lean tools, helping the team focus on the issue and to follow the problem solving procedure.

Chennai, Tamil Nadu, India

Tube Products of India, part of the Murugappa Group, is the Tier 1 supplier of cross-car beams and side-impact beams to Hyundai and Tata Motors. They are also the manufacturers of Front Fork tubes for motorbikes (Royal Enfield).- Developed and implemented walk patterns leading to an increase in production of 10 parts per hour. This resulted in a decrease in overtime cost by $400/day.- Assisted with implementation of kanban systems for sub-assemblies leading to a 20% reduction in WIP.- Achieved a 28% reduction in scrap generated, leading to $2700 monthly savings, by using 8D problem-solving.- Utilized Oracle ERP for creating purchase orders, change orders, bill of materials (BOM), and asset management.- Reduced variability by 15% in the tube drawing process, using six sigma techniques like DOE, Gage R&R, and SPC.- Evaluated engineering projects to optimize flow, reduce waste, and minimize labor cost by utilizing work simulation and pre-determined time measurement techniques.- Conducted PFMEA on cold roll forming process to identify potential issues and provided engineering solutions.- Improved workforce efficiency by 9% by designing standard operator balancing charts and SOPs.

Chennai, Tamil Nadu, India

MRV Industries is the Tier-II Supplier of car door frame parts to Hyundai, Toyota, Nissan, & Isuzu.- Reduced mold change over time using SMED and achieved a 15% increase in throughput.- Optimized operation sequence, which reduced the process cycle time and improved OEE by 10%.- Reduced machine downtime by 57% and achieved $233K annual savings through a six-sigma project.- Revised CAD warehouse drawings to incorporate facility layout changes for efficient space utilization.- Assisted with cost analysis and make/buy decisions for new procurements and improvement projects.- Performed GAP analysis on monthly sales and utilized Tableau to present research-backed opinions.- Improved material handling efficiency by streamlining tasks and reduced cycle time by three seconds.- Worked on slotting & reslotting products by analyzing historic outbound data for high-velocity SKUs.- Created capacity and manpower allocation models using MATLAB and Excel Macros.

Chennai, Tamil Nadu, India

- Worked on value stream mapping for the car door frames section. - Assisted with data collection and analysis of key performance indicators in the production line.- Trained on manufacturing processes such as sheet metal forming, roll forming, TIG & MIG welding.

Master Of Science - Ms, Industrial Engineering

Bachelor Of Engineering - Be, Mechanical Engineering