Project LeadershipLed and managed cross-functional project teams (CFT) to deliver projects on time, within scope, and within budget.Defined project goals, objectives, and deliverables that support business objectives in collaboration with senior management and stakeholders.Developed detailed project plans, including timelines, resource allocation, and risk management strategies.Monitored project progress, identify risks, and implement mitigation strategies to ensure successful project completion.Process DevelopmentDeveloped and implement standardized processes and best practices to enhance efficiency and reduce operational costs.Facilitated continuous improvement initiatives and drive Lean and Six Sigma methodologies to optimize manufacturing operations.Team ManagementFostered a collaborative team environment by guiding, mentoring, and motivating team members.Facilitated communication and collaboration among team members from different departments, including engineering, production, quality, and supply chain.Conducted regular team meetings, provide clear direction, and ensure alignment with project goals and company objectives.Identified skill gaps within the team and recommend training or development programs to enhance team performance.Stakeholder CommunicationTrained responsible project engineers to establish proper communication channels with internal and external stakeholders

Production Planning: Analyze program and project schedule requirements to formulate production plans for Fixed Wing VTOL UAVsSchedule Updates: Revise and update production schedules to reflect the most recent purchase contract (PC) and sale order versionsERP/MRP Schedule Management: Update schedules and manufacturing documentation in the ERP/MRP system, ensuring they incorporate the latest manufacturing developments and process changesMaterial Requirements Management: Plan, schedule, monitor, and control material requirements for production, including organizing manufacturing kitsMaterial Shortage Mitigation: Examine material shortages and collaborate with Supply Chain, Quality teams, and other stakeholders to address and reduce material shortage risksShortage Impact Management: Identify, communicate, and alleviate the impact of any material shortagesDynamic Schedule Coordination: Manage the variability in manufacturing, material, and tool schedules. Coordinate with internal stakeholders to address dynamic schedule requests from customersJob Order Processing: Issue job orders and production orders in the ERP/MRP system, ensuring all necessary details for execution are includedWeekly Resource and Kitting Plans: Develop weekly resource and kitting plans, working with manufacturing stakeholders to ensure acceptance and implementationDaily Production Monitoring: Track production progress daily and manage data for MIS reporting, ensuring accurate and timely updatesResource Availability Review: Assess resource availability daily, evaluate its impact on production, and adjust manufacturing operations as neededInventory Management: Monitor consumption patterns and forecasts at customer sites, manage inventory levels, and take action to ensure inventory does not fall below minimum levelsStakeholder Communication: Inform stakeholders and leadership of any impacts related to staff, tools, materials, or infrastructure, and collaborates on finding solutions

Evaluated existing manufacturing processes and implemented changes to reduce manufacturing time and costs, while improving qualityImproved manufacturing efficiency by analyzing and planning workflow, space requirements, and equipment layoutAssured product and process quality by designing testing methods for finished product and process capabilitiesProvided manufacturing decision-making by working with the Materials Planners, Manufacturing Leads and Operations DirectorManaged the transition process of the New Product Designs (NPD) from engineering to production. Led a team of 10 Manufacturing Technicians and Leads, to plan assembly production, and reduce manufacturing waste (Inventory, Transportation, Motion, Waiting, Over production, Over processing, and Defects)Developed and managed the transition process of new product designs and assembly instructions from R&D/ Engineering to ProductionDefine and coordinate the generation of all required manufacturing documentation such as work instructions, test procedures, data summariesSupported the assembly, integration, and verification of electronic, mechanical, opto-mechanical, and opto-electronic assemblies

Participated in various training sessions such as Seat Belt Technology training, Quality training, and Workplace Safety trainingDocumented the Change Point Control (CPC) and Defect Containment Sheets whenever the machines go through maintenance and /or defect is found in the raw material or finished goods either from the supplier or from other assembly departmentsMailed the Production Instruction Kanbans (PIK) and Production Withdrawal Kanbans (PWK) from or to the various station for Just In Time (JIT) production and to avoid the Muda(waste)Calculated the scrap rating, production efficiency rating every day to input accurate and precise information into the system and achieve Heijunka

Planned and managed all the elements of production in the Buckle Finishing Department by assessing and analyzing current production methods and processesIncorporated the Engineering Change Document for customer requested change or major level up to modify the tooling and processCreated the Capital Expenditure Authorization and Fund Requests to purchase, outsource and implement the new processes, tooling and updated the machine in accordance with the product testing requirements Supported the TPS activities through labor analysis (line balance creation, standard work), process improvements, material flow analysis at the cell and plant level in addition to project economic justifications for capital expenditure procurements Participated in the design and developments of the assembly process along with the machines, tools, and fixtures with the vision program setup and convey the requirements to the controls group regarding the PLC program setup Converted two cells with one shift capacity each to one cell with two-shift capacity, overcoming the challenges to meet the tooling requirements for all the products, which resulted in plant floor space availability of about 20 ftLiaised with design, quality, and maintenance department to implement new ideas and improve cell throughput from 1100 to 1350 parts per shift, increasing the cell efficiency by 22% Reduced the cycle time from 23.18 sec to 19.20 sec by eliminating non-value-added elemental tasks, resulting in the increase in production volume from 47 Parts/ Associate / Hour (P/A/H) to 58 P/A/H Assisted controls department in setting up vision detection systems and PLC programming for various assembly lines Performed root cause analysis on the frequent downtime and resets caused in the manufacturing process or mechanical failure on the machines, reduced the production loss to 28% from 35%

Conceptualized the projects to final production by framing the idea and modeling new mechanical systems and machines using SolidWorks and Solid EdgeWorked on research and development (R&D) of the optomechanical assemblies to support continuous improvement with an accuracy of 10 microns using CAM, and ZemaxGenerated design schedules using Gantt charts to prepare for pre-production prototyping and manufacturing process to achieve final product within specificationsEngineered over 7 projects worth 20 million CAD including Beam Director Optical Channel, Beam Delivery System, and Laser Beam Optical Director

Modeled the new 3D designs and updated the old designs to standardize the design parameters and production standardsCreated the 2D drawings, list of parts required outsourcing, and Bill of Materials as required by the production and assembly department Planned, developed, and modified test plans to detect and diagnose errors in accordance with the company’s quality standards and customers’ requirements in hermetically sealed environmentApplied Design for Manufacturing (DFM) and Design for Assembly (DFA) technique starting design phase to the final fabrication of the components, assemblies, jigs and fixtures, and sub-assemblies