Engineer Six Sigma
Resume:
PRAVEEN NARASIMHAN
N**W***** Saddlebrook Drive, #206
Pewaukee, Wisconsin 53072
praveennarasimhan@ya
hoo.com
CAREER PROFILE
Multi-faceted Lean Leader with a strong quality/operations background
spanning diverse processes, machinery, assembly methods and business
improvement initiatives. Delivers cost savings and productivity gains
using Value Stream Mapping, 5S, Visual Management, Standard Work,
Layout, FIFO, Kanban, SMED, Six Sigma DMAIC, Kaizen, SOP and
Data/Measurement tools. Strong auditing experience including customer
TS and AS 9100 compliance and using 8D, A3 and 5 Why problem solving
for corrective actions and continuous improvement. Successfully
promoted culture changes with Employee Involvement strategies and
frontline/managerial training.
PROFESSIONAL EXPERIENCE
2012 to 2013: MTE CORPORATION - Menomonee Falls, Wisconsin
International supplier of line/load reactors, passive harmonic filters,
Matrix Active Pure sine harmonic filters and Sine wave motor protection
filter products designed to improve the reliability of power electronic
systems.
Lean Champion
Develop and implement Lean Deployment strategy across the corporate
functions and manufacturing facility involving 100 employees. Duties
includes: Develop Standard Work Cells; business systems to support
company's strategies; manage manufacturing engineer and capital equipment
installation.
. Managed Implementation of $250K Foil winding machine by
coordinating activities with the various internal cross-functional
teams and international supplier.
. Developed Kaizen roadmap of the company to support the strategic
initiatives like expanding business into new markets, move
manufacturing close to customer locations and increase
productivity.
. Updated managerial standard work to integrate GEMBA plant floor
walks into their regular schedules for identifying waste and giving
attention to corrective action plans.
. Implemented SQDC boards across all the cells to track daily metrics
and cultivate a continuous Improvement Culture in the manufacturing
facility.
. Initiated Corporate Business system Kaizen's: Transfer products to
Offshore locations, update costing in MRP for various changes,
Visual management of Prototyping process and minimize Commercial
launch process time.
. Facilitated Kaizen events in the assembly area and created standard
work cells with POU and Line side materials to implement 1 piece
flow. The cell was created as model cell for the plant and improved
productivity by 48% and inventory turns by 5.
. Judged the kanban implementation of different candidates and
certified them as subject matter expert based on sustainment of
kaizen and achievement of the goals
. Created the plant layout and operations vision of the Menomonee
falls for the next 3 years based on product mix, marketing and
sales strategy
2010 to 2012: GKN SINTER METALS - Menomonee Falls, Wisconsin
$1B powder metal parts manufacturer supplying automotive, appliance,
power tool, lawn & garden and diverse OEM markets and part of a $7B
diversified global industrial conglomerate.
Lean Manager
Drove Lean initiatives across 3 facilities encompassing precision
machining, powder metal compaction and tool & die operations involving
125 employees. Duties featured: identifying and leading
productivity/savings projects; facilitating Kaizen and Six Sigma
events; customer quality problem solving; providing expertise/new
strategies to management; training programs; data collection and
reporting; frontline coaching; and daily reinforcement efforts.
. Exceeded cost savings and productivity targets of $400k+ in 2010
and 2011, with 2012 results running $17k above monthly goals.
. Facilitated multi-shift Kaizen at the powder metal facility
resulting in a new layout of the secondary process areas, which
yielded a 15% direct labor improvement due to a 45%, decrease in
part travel distance.
. Initiated Business Process Improvements including: reducing Sales
Office quoting lead time by 15 days; and improving Quality Audit
readiness by developing a dedicated problem solving system for
common customer concerns and promoting 30 day corrective action
turnaround.
. Increased uptime 30% by leading Six Sigma program in tool & die.
Mentored program candidates in identifying the root cause of EDM
machine issues producing excess process variation.
. Trained site teams and personnel on problem solving concepts
including 8D, A3 and 5 Why methods. Shrank inventory variation from
2.4% to 0.8% by using A3 concepts and tools.
. Devised 5-year plant strategy spanning continuous improvement,
manufacturing process capital requirements, sales, quality and
purchasing. Created and monitored the supporting annual plans and
performance.
. Eliminated bottlenecks between powder metal press and sintering
areas. Reduced WIP 20% by balancing and smoothing the flow by
creating FIFO lanes and limiting/correcting the number of product
staging carts.
. Advanced the Production Manager Continuous Improvement Training by
developing program materials and assisting candidates with case
study and storyboard preparation.
. Prepared key monthly reports, which were used in management
planning/issue identification, including KPI's, Overall Equipment
Effectiveness, Delivery Schedule Attainment, First Pass Quality,
People Productivity and Stock Turns. Facilitated Kaizen introducing
FIFO to increase powder metal stock storage by 5 turns
2006 to 2009: PRAXAIR SURFACE TECHNOLOGIES - Indianapolis, Indiana
Producer of high performance coatings and surface processes for aerospace
and industrial applications
Continuous Improvement Engineer
Duties emphasized implementing Praxair's Operational Excellence System
integrating Lean, supply chain, quality and operating best practices.
Pivotal role in conducting internal audits per AS 9100 and NADCAP
standards, as well as auditing the implementation of the OpX System at
other facilities.
. Introduced visual boards in streamlining the scheduling processes
to improve resource utilization. Increased utilization 20% by
calculating equipment capacity and initiating Managing for Daily
Improvement.
. Partnered with Cessna on a Supply Chain Extended Value Stream
Mapping Event. Results led to qualifying new local suppliers
shrinking travel related lead times by 2 weeks and a 50% reduction
in batch size
. Saved $60k annually by leading collaboration with Grainger in
implementing a Vendor Managed Inventory of production
consumables/supplies. This "first time" VMI program became a
corporate model.
. Performed DMAIC project using Minitab software to identify wear
cycles for rebuilding plasma-coating torches. Saved 850 labor hours
and $25k in supplies per year, while also improving the rebuild
processes.
2004 to 2006: HERAEUS ELECTRO-NITE COMPANY - Peru, Indiana
Leader in developing sensors, measurement and control devices for molten
metal processes
Manufacturing Engineer
Developed engineering solutions for 4 sensor production lines.
Priorities emphasized: integrating Demand Flow Technology into
production processes; creating standard job instructions; and
structuring the Engineering Change Request processes for new product
programs. Served as Substitute Supervisor for a team of 25 employees.
. Supported new product launches by utilizing Design of Experiment
methods to determine the correct pressure and temperature settings
per different materials. Established the proper composition of
powder mixtures when combined with petroleum-based mixers.
. Defined labor requirements using DFT concepts in calculating the
maximum capacity of molding machinery. Also, improved labor
utilization/flexibility by changing packaging methods to remove non-
value added tasks.
. Reduced powder inventories and improved cash flow $25k by creating
plant floor staging areas and visual tools providing the
availability of raw materials.
EDUCATION and PROFESSIONAL DEVELOPMENT
Master of Science, Engineering - 2004 - Kettering University f/k/a GMI -
Flint, Michigan
. Served as an Adjunct Lab Lecturer - Industrial Manufacturing
Department, providing classroom and lab instruction to 60 students in:
Machining; Metal Joining; Castings; and Plastic Injection Molding.
Bachelor of Production Engineering - 2001 - Bharathiar University -
Coimbatore, India
Six Sigma Green Belt - Praxair, 2006; Lean Practitioner - LVSI, 2008;
Continuous Improvement Leader - GKN, 2010; PFMEA, APQP & PPAP - AIAG, 2012;
TQM - Quality Training Institute; 2007; Demand Flow Technology - JCIT,
2005; Basic Powder Metallurgy - MPIF, 2010; GE's Supplier's Standard Work
Kaizen - Shingijutsu Consultants, 2009
AutoCAD v12/14; MS Project; Minitab 14; BAAN; ARENA; MS-Visio; MS Office
Suite; Lotus Notes
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