Customer Service Six Sigma

Reji Koshy, BSME, MS in MFG Systems Management (SMU)

**** ********** **, *******, ** 75088 Cell: 214-***-****, USA **********@*****.***

Six sigma manufacturing and Lean leader with 23+ years of experience in lean LEAN

MANUFACTURING, PROCESS ENGINEERING, MANUFACTURING ENGINEERING, QUALITY

ENGINEERING, SUPPLY CHAIN OPERATIONS and OPERATIONS MANGEMENT.

Six Sigma Green Belt Certified.

Effective in implementing and training various departments lean methodologies/

continuous improvement best known methods. Strong computer skills, excellent

multitasking and organization aptitudes, and proven ability to solve complex problems.

Broad spectrum of experience in Low and High Volume Production; in various fields such

as Aero Space, Semiconductor, Electronic and Heavy Machines.

Extensive experience in TQM, TPM, 6Sigma, 5S, Poke-Yoke, optimum process

development, process improvement, project management, data analysis, root cause

analysis, commonality analysis and cycle time improvement. Effective communicator

and problem solver. Enjoy coordinating the efforts of multiple departments.

EXPERIENCE

GENESIS LED SOLUTIONS INC. – Plano, TX

LED Lighting Technology/Manufacturing Company

Order Fulfillment Leader, August 2010– Present

Leading various simultaneous projects for improved customer relations, BOM cost reduction,

cycle time reduction, lead time reduction, waste management, continuous improvement and

lean manufacturing implementation. Conducted Value Stream Mapping in product assembly,

re-arranged work cell for improved efficiency. Noticed the product assembly time went down

from 30 minutes to 20 minutes because of this work cell re-arrangement. Implemented 5S in

the office and the assembly area with weekly routines to maintain the standardization.

CYTEC ENGINERED MATERIALS INC (CEM). – Greenville, TX

World leader in manufacturing Carbon Composite Materials (Prepreg) for Aerospace

Applications.

Senior Manufacturing/Process Engineer,, September 2007 to August 2010

Responsible for Carbon composite materials manufacturing used in Air Craft Industries.

Lead the evaluation of LEAN projects, systemic process problems and recommending solutions.

Other responsibilities include customer service requests, implementation of process and

machine solutions, project definition, project management and execution.

Practice and train Six Sigma manufacturing engineering principles to increase production line

efficiency, waste reduction, reduce cost, and improve cycle time and output. 5S Champion for

the manufacturing and office areas. Implemented several Poke-Yoke techniques to improve the

safety and reduce waste.

Created SOPs (Standard Operating Procedures) for five manufacturing equipment. Performed

time studies and Line lay out studies, improved the machine setup time by 20%. Standardized

operations across different machines. Implemented TPM (Total Productive Maintenance) on

critical machines.

Lean Project Examples I lead at Cytec:

1) Eliminated the down time (8 hrs. per week) for Treater1 and Treater2 machines for

Compaction Rolls Teflon change over by implementing plasma coatings for these rollers.

2) Eliminated the use of paper in compaction for selected products which resulted in cycle

time improvement (1hr), paper inventory reduction and BOM cost reduction (~5%).

3) Implemented online Poly Inspection to reduce customer return/complaints and reworks

by 25%.

4) Implemented TPM on STL, Treater1, Treater2 and FX machines to reduce customer

complaints by 20% and safety improvement by 10%.

5) Reduced the machine down time by 15% for PMR run every quarter by proper man

hour/OT schedules and making sure all the material is staged properly.

6) Introduced Poke-Yoke for specific gravity, replaced manual specific gravity adjustment

with automated specific adjustment.

Note: Treater1, Treater2, FX and STL are different Prepreg manufacturing lines.

TEXAS INSTRUMENTS INC (TI). – Dallas, TX

World leader in DSP and Analog Technologies.

Process Engineer, June 1995 to 2007 September

Practice process development/sustaining engineering principles to increase production line

efficiency, reduce cost, and improve cycle time and output. Responsible for process

development, training and production ramp for various process operations. Hands-on

experience in developing and optimizing different processes for cutting edge technologies

across different equipment sets.

Delivered robust unit processes with emphasis on solid manufacturability (control, cycle time,

high yields, low costs and predictable output). Have a strong grasp of developing and existing

technologies and the importance of its use in business practices.

Implemented TPM for high capital equipment in the plant. Fanned out standardized BKM (Best

Known Methods) across departments. Performed Critical skills emphasized included solid

project planning/management fundamentals, process control, metrics/review, structured

problem solving and rapid issue resolution. Day-to-day support leveraged SPC, DOE’s,

structured problem solving, planning, training and teamwork to resolve manufacturing issues.

Enable company to increase PFO by $3.7 M/year through process yield improvement

by developing a new process.

Enable company to increase PFO by $2.5 M/year through cycle time improvement by

process mixing in two different equipment sets previously dedicated for separate processes.

Enable company to increase PFO by $1 M/year through cycle time improvement by

introducing metrology sampling.

Enable company to increase revenue by $2 M/year through scrap reduction by process

optimization.

Introduced Poke-Yoke (mistake proof methodology) to reduce scrap/improve process

yield through ‘guard band’ and Lot-V introduction.

September’89-June’94: Deputy Manager, NC Machines Private Limited, Kochi, India.

Responsible for Quality Assurance, shift performance, WIP management, shift staffing,

personnel management and employee development. Supported vendor development and

assembly; emphasizing quality, training, planning, documentation, and continuous

improvement/team results. Personnel responsibilities included day-to-day employee issues,

conflict management, hiring, employee evaluation, ranking and development.

EDUCATION:

MS in manufacturing systems management, Jan 2004-Dec 2007

SMU, Dallas, TX.

BS (Mechanical Engineering), Aug 1984-Sept 1988

National Institute of Technology, Calicut, India.

Six Sigma Green Belt Certified by the Cytec Master Black Belts.

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