Industrial Manufacturing Engineer

Varun Kale

Email: ac1vo2@r.postjobfree.com Phone: 540-***-****

*** ******** *** ** ********** VA 24060

Education

MS in Industrial & Systems Engineering, Aug 2015- May 2017

Virginia Tech, Blacksburg, 3.4

BS in Production Engineering, Aug 2010- May 2014

University of Pune, 3.8

Work Experience

Cummins Inc.

Industrial Engineer Intern 05/16 - 07/16

Redesigned manpower calculation and planning system for all engine lines, reduced calculation time and effort by 50%

Data inconsistencies & version errors eliminated by auto-updating from MPS, Access and HR data.

Participated in shop floor meetings to analyze & optimize workload distribution

Assisted in troubleshooting activities using root cause analysis, analyzing & updating processes.

Performed data collection and reporting for Total Productive Maintenance (TPM) projects

Fiat Chrysler Automobiles

Industrial Engineer Co-op 01/14 - 06/14

Assisted in new product launch in Assembly to streamline the introduction and troubleshoot process issues; suggested & implemented improvements in processes and logistics

Responsible for cycle time reduction project of 3 stations, reduced time by 15%.

Assisted in Kaizen and 5S initiatives for all physical material flow for the quality line facilitating Just-In-Time and Push/Pull system.

Participated in designing kitting & supermarket area using AutoCAD for new product launch.

Performed MTM-UAS analysis on quality line to benchmark standard work with group standards.

Responsible for improvement projects of Standard Operations of emission test stations to reduce ergonomic and safety hazards.

Trained in Fiat Production System, Ticon, SAP, MTM, MODAPTS, and ERP modules.

Larsen & Toubro

Industrial Engineer Co-op 07/12 - 12/12

Responsible for material flow improvement project from warehouse to Assembly 1 area.

Designed and recommended part transport and staging solutions for small components such as ergonomic gravity trolleys, interlocking individual skates for bulky boxed materials.

Performed documentation of Standard Operating Procedures and Standard work instructions

Performed material flow work measurements to analyze and improve processes and reduce NVAs

Supported production line control team in implementing laser marking & streamlining of large components material flow.

Implemented layout optimization in Delmia; simulated improvement scenarios (Visual factory) to recommend the optimized layout and material flow process.

Assisted in value stream mapping of warehousing operations for future process improvement projects.

Relevant Projects

Littlefield Technologies Online Factory 01/16 - 05/16

Graduate Project

Real time control of order scheduling, inventory level, EOQ, lead time management, & delivery

Balance capacity and bottleneck stations during order surges and downtime.

Decide strategy to ensure no back-ordering, on-time deliveries of ’hot’ orders.

VT Whittemore Fab, Blacksburg VA 08/16 - 12/16

Modeling and Analysis of operations in AutoMOD & AutoSched

Simulated Fab model for 108 processes including AMHS with complex re-entrant flows.

Minimum cycle time achieved after evaluating 8 dispatching & sequencing rules.

Inventory impact studied; lot idling techniques employed at down machines

Optimized Automated Material Handling System to achieve better route and pickup/drop times.

VT CEED, Virginia Tech 01/16-04/16

Performance Measurement and Quality Improvement

Implemented Malcom Baldridge, SIPOC & survey to identify KPIs for targeted improvements.

Performed Root Cause Analysis to investigate hidden causes of low mentee satisfaction.

Recommended KPI based training of mentors to improve interaction quality with mentees.

Customer & Stakeholder satisfaction improved by 40% based on survey data.

Recommended automation for matching mentors with mentee to reduce bias and low satisfaction.

Related Skills

Software: AutoCAD, Catia, NX, AutoMOD(simulation), Delmia (3D simulation), MES, MS Office, Visio, Tableau

Areas: Proficient in material flow optimization, continuous improvement, work standards, work measurement, SOPs, manpower planning, process improvement, inventory management.

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