As a Sr. Industrial Engineer at Custom Service Manufacturing (CSM), I lead continuous improvement initiatives to optimize operations and drive efficiency across various processes. My role involves:Leading projects focused on process improvement, automation, and the implementation of innovative solutions.Handling automation implementation, from concept development to full integration.Overseeing quality issues, conducting root cause analysis, and implementing corrective actions to enhance product quality.Providing estimates and quotes for new projects while managing feasibility studies and conducting experiments to ensure project success.Collaborating with 3M on new projects and programs to align with their standards and requirements.Training employees on new equipment and developing comprehensive standard operating procedures and work instructions.I am dedicated to fostering a culture of continuous improvement and operational excellence to deliver superior results for CSM and its partners.

Responsibilities:  Document PPAP for new and engineered changed parts as per APQP process adherence with IATF 16949 standards. Resolved root cause and corrective actions with 8D method problem solving and implemented temporary and permanent countermeasures.  As a certified internal quality auditor, performed weekly and monthly internal audits to prevent quality related concerns. Troubleshoot CNC Wardjet machine, Cognex line scan camera, Imperia 2D barcode printing system, Mettler Toledo checkweigher and Keyence camera system Conducted monthly meetings to discuss and analyze the monthly performance charts of key metrics. Decreased highly ranked RPN in PFMEA for die cut station, CNC machine and laminator workstation.  Supported team to qualify the organization for IATF 16949 certification.  Performed several small kaizen projects to decrease the process time at changeovers, documentation work and to enhance the quality of the product.Continuous Improvement projects: Reduced cycle time by 35% and increased the productivity by design & implementing automatic mixing ILA station at Laminator workstation and by modifying the sequence of work process steps. Conducted 5S for die and gauge location for easy retrieval and working on automating inventory with barcode and scanner system. Design and developed the dynamic caliper system where it increased the sorting capacity from 8,000 parts per shift to 25,000 parts per shift (ongoing project).

 Creating work instructions for every workstation with an idea of displaying each step of operation in the monitor with relative to the standard time taken by the operator to complete the operation  Performed time studies and reduced the cycle time to increase the production from 26 to 35 machines per week.  Re-arranged the workstation using 5S to make easy retrieval of parts for the operator & performed monthly quality audits  Resolved daily quality concerns with root cause analysis tools like 5 why’s & fish bone diagram and implemented temporary and permanent countermeasures.

 Programmed CNC codes and modified existing codes for Turbines Discs, Compressor Discs in turning operation Created Work Instruction Sheets and routing sheets Drive progress in WCM pillars mainly on Focused Improvement and Workplace Organization pillars Implemented and maintained 5S in the plant  Executed PDCA by conducting tests for new programs to machine new parts and approving the program Performed RCA (Root Cause Analysis) for defects in parts while testing new programs Developed Operation sheets, Tool sheets & Blue Prints using GD&T Performed time studies on 100 turbine disc parts in turning operation and analyzed data using MINITAB Based on time studies, rebalanced the line and improved the labor utilization Analyzed current OEE of the machine and increased it by 8% Reduced production cycle time by 20%

 Implemented Poka-Yoke for efficient sequential production to optimize OEE at kitting and to reduce assembly errors Performed time studies to eliminate non-value-added work and changed the length of wire harness for easy installation of lamps into vehicle Performed process audits at supplier for process failures and quality improvements on new product launches Modeled the exterior lamps and released design using NX-CAD & Teamcenter and optimized facility layout with AutoCAD Spearheaded cost reduction activity to achieve 3-3-3 target (4.5% cost reduction) and processed ECRs– changing design of lamps, localization and change of material for lamps Conducted tests for tolerance specifications (Gage R&R) on all lamp parts using Joint Check gauges Utilized 7QC & 8D for root cause analysis and implemented temporary & permanent countermeasures– changing snap fit to screw fit between reflector and lens  Developed concise Bill of Materials (BOM) for lamps with master check for each build activity (VC, PT, SOP) Conducted production trials in assembly line for each modification in design till Start of Production Applied Kaizen to reduce costs while integrating standard design specifications of Renault & Nissan Benchmarked all existing Indian cars and applied best practices in utilizing trend catch up activity Analyzed PFMEA, DFMEA, Cpk and SPC charts from Automotive Tier -1 suppliers to maintain Six Sigma Verified PPAP documents for change in design of parts and got approval for PSW (Part Submission Warrant) Identified and resolved problems of vehicle integration on production floor Pioneered H79N and L02B MC project by performing localization of lamp from knock down part to local part Achieved patent proposal in Indian road conditions of ‘focus lamp using on side view mirror for tire change at night time’

Analysis of overall plant efficiency and water flow path through combined cycle :This project involved generating power by using combined cycle refers to the combination of Rankine cycle and Brayton cycle. Calculations of water flow rates at each stage like Turbine, Compressor, and Boiler was undertaken and finding out effective and efficient water flow path through the cycle for generating electricity.