Customer Service Sales

Nigamesh Arya

***** ******** ***** *****, ******, MI 48187, (H) 734-***-****, (C) 313

***-****, (E-mail) ******@*******.***

Objective:

To seek a challenging career requiring my expertise in Manufacturing

Engineering, Operations Management, Metallurgy, Quality and Sales.

SKILLS:

Multi Plant Manufacturing Engineering, Operations Management, Tool and

Plant Maintenance support.

Improve productivity and reduce costs - SMED & KAIZEN & JIT PLANNING &

MAPING.

Implement Hands on and Lean Manufacturing, thru both mechanical &

electronic logic.

New Plant Project Management/Plant Engineering.

Advanced Engineering and Project Management.

Application of Metallurgical Sciences and Manufacturing Research

Methodology including DOE.

Quality Management - ISO, QS, APQP, PPAP, FMEA, 8D etc.

Sales and Product Development of steel products including such as

Curvilinear Laser Welds.

Sales, Customer Service, Technical Reporting & Follow-up.

Participate in early stages of OEM (Chrysler, Ford, GM) tool tree processes

to develop cost savings for increased Sales, Tooling and Manufacturing .

Successfully Launch Stamping Programs & Tooling Launches for the OEM

programs.

Purchase of Stamping Panel Tools Mostly Designed in (CATIA V4 & V5).

Cost effective procurement of Tools, Dies, & Plant Equipment.

Follow-up the Procurement, Design, Build and Tryout of Stamping Tooling,

Gages and Fixtures, both Locally and Internationally, & then -successfully

launch these tools for Production in various Manufacturing Plants both in

our Internal Plants & Customer Facilities.

SUMMARY:

* MANUFACTURING & OPERATIONS MANAGEMENT, LEAN MANUFACTURING and ADV.

ENGINEERING: Create unique solution for manufacture of Truck Fenders thus

saving the OEM 30% in their press shop manufacturing cost. Designed and

Implemented Innovative Manufacturing Solutions using Man, Machine, &

Electronic Logic. Created 20% Process Cost Reductions with Lean

Manufacturing Techniques - (such as, SMED - KAIZEN, Robotic Pick-and Place,

Transfer Gate Systems, Gravity Fall, Rail Track Turnstiles, Totes etc.).

Increase the production out put from the presses by 30% thru the

Intelligent and Creative Design of Tools and Dies (such as In Line Dual

Tandems with Proprietary Magnetic Extraction Systems) which then became

capable of using creative Press Logic. By the Application of Advanced

Engineering Principles and Alteration of Part Geometry, Provided Improved

Materials Yields of 10% to the Customer's worth several Million Dollars.

Integrate Plant Manufacturing, Plant Maintenance and Tool and Die

Maintenance for 20% Reduction in Costs and also increased Productivity.

Conduct Cycle Times studies on Press Speed cycles for 10% increase in

productivity.

* METALLURGY, QUALITY, CUSTOMER SERVICE SALES & GROWTH: Evaluate the

applications of raw steel coil materials in OEM manufacturing - HSLA and

Carbon steels. Study panel formability with customers and suppliers. Use

advanced metallurgical science principles to increase tool steel life and

reduce manufacturing cost by reduced maintenance cycles and increased up

time of the tools. Research tool steel heat-treating processes for proper

selection of tool materials in OEM tooling applications. Study and

implement tool coatings for improved tool life cycles. Qualify and Quantify

material selection and inspection of major steel panels (both for exposed

and frame applications) for the OEM. On floor Draw Panel validation studies

in OEM manufacturing facilities, and also both at local and international

tooling suppliers. With application of advanced metallurgical principles

and alteration of part geometry provided Improved Materials Yields to the

customers, and in one case a 5% yield savings resulted in savings worth

several Million Dollars. Write Design of Experiments to validate cost

saving processes for both internal and external applications. Created

unique solutions (in early 1980s) in the use of Coil Steel and Stampings

panels which helped Kasle Steel become the largest steel supplier at Flint

Metal Fabricating facility and thus creating additional revenues of up to $

50 M/yr. Attend with the customers their pre-launch tool tree process to

define possible costs savings in their developmental process rather than

later on where the cost of changes escalates the launch cost, and thus

create partnerships to achieve sales growth. These ideas have helped the

corporation grow from 1 plant to 6 - (600)% plants over the years. Assist

the customer's in their quality, tooling and material use

requirements/expectations. Develop sales partnerships with customers thru

customer service to the OEM. Implement quality programs including the first

self directed such corporate venture utilizing SPC.

* MANAGE on time PROGRAM/TOOLING LAUNCHES: Manage build and launch

Stamping Panel Tools (several of these tools were designed with unique 1st

time Industry wide capabilities to achieve productivity gains of up to 30%)

for several OEM Programs (including the Cost Effective in plant

Manufacturing after the post launch process) including the following few:

Tools for panels made from both Steel and Aluminum, such as Body Sides

(Outers and Inners), Doors (Outers and Inners), Hoods (Outers and Inners),

Lift Gates (Outers and Inners), Fenders, Wheel Houses, Header Panels,

Roofs, Control Arms, Axles, Automotive Power-train Converters, Clutch

Plates, Pressure Plates, Radiator Enclosures, Wheels, Curvilinear Laser

Welds for - platforms such as the X Car, CT-20 etc in early 1980s and

others through the present generation WK, RT, DS, P-415, P-473, D219-258, D

471-472, GM H, GMX 966, GMX 901, GMX 521 etc. have been successfully

launched along with Appliance Compressor Systems, Pedestal and Elevation

Bases, and Water Heater systems and also aluminum discs for the recording

industry.

* PLANT PROJECT MANAGEMENT, CAPITAL BUDGETTING and SPENDING: Design and

create efficient plant layouts for various new plant locations, including

the Manufacturing Cells utilizing the proper Flow and Staging of Materials

from Raw to Ready to ship after Manufacturing, so that the JIT applications

will be successful and the inventory costs minimized. Procure/Purchase

Capital Equipment (integrate previously owned capital equipment from

different sources, re-build it, and use it just as new, in manufacturing

locations thus saving upwards of $ 2,000,000 in capital costs of each press

line) and Tools and Dies both locally and internationally within the set

budgets and timing. Launched the 1st Exposed Panel stamping facility out

side of the OEM's internal manufacturing base in 1984 to service Buick City

Manufacturing facility thus an increase of corporate sales by 25%.

* DESIGN and BUILD MATERIAL HANDLING SYSTEMS: Implement unique design

for off loading parts from in-plant manufacturing equipment, and then to re-

load into the customer's equipment. One such unique system saved an OEM

stamping plant $ 6,000,000 in their initial stamping plant's start up

costs. Also built new generation internal plant material handling systems

for maximum productivity, press utilization, and plant efficiency.

PROFESSIONAL EXPERIENCE KASLE STEEL CORPORATION Jan 1977

thru Nov 2008

* Designed a unique 2/stroke fender capability for the new F 250-450

(2011) series trucks for Kentucky Truck thus saving the OEM 30% in their

transfer press cost to produce 2 fenders for each truck (one hit = 2

fenders = 1 Truck).

* Implement a $ 4,000,000+ saving for the P-473 truck door inner thru

stamping tool replacement and change in geometry.

* Designed a common die concept for a new program launch for 2010 by

redesign of the 3 panels to a common acceptable design and thus reduce the

startup tool cost by $ 200,000 - 66%.

* Oversee and coordinate the manufacturing activities and implement

common cost savings for all the manufacturing facilities in the corporation

thus reducing the cost per ton by up to $ 2 per ton.

* Traveled overseas for tooling procurement (including the build and

follow-up) thus saving the OEM 15%.

* Implemented unique tooling solutions for curvilinear laser welds thus

increasing sales by $ 2,000,000.

* Implement unique magnetic extraction for tools and thus be able to

produce 2 parts with one press stroke, where previously only 1 could have

been thus improving productivity by 30%.

* Study of the unique scalloped edge concept for material yield saving

in steel panels by altering the straight edge cut-off to a unique rolling

hill edge contour cut-off to improve yield by 10%.

* Directed FMEA and PPAP studies for all program launches, and also

coordinated the launch of the ISO system.

* Design unique flow systems for JIT capability at the new manufacturing

facility in Indiana for 10% increased up time.

* Improve tooling life between runs by up to three (3) times-300%.

* Develop steel product strategies and unique solutions during the OEM

pre-launch cycles, and by attending the tool tree meetings where no other

competitors ever came thus a competitive advantage and increased sales by $

2,500,000.

* Conduct DOE studies at customer's manufacturing establishments for 10%

cost savings to the customer by using our products.

* As a Program Manager purchased stamping tooling at substantial savings

of up to 30% by conducting detailed RFQs.

* Study and implement efficient plant layouts for unique manufacturing

solutions that will reduce costs and provide JIT and Trucking Services at

substantial cost savings.

* Implemented the design and build of material handling systems for our

plant as loading base, and then unloading and feeding at the customer's

that resulted in an up-front cost saving of $ 6,000,000, and thus an award

to supply products worth $ 5,000,000 and to build a new manufacturing

facility.

* Study the alternatives between new and re-build equipment, and then

specify the re-built option for new manufacturing lines with savings up to

$ 2,000,000 per line, a total of 8 such lines were launched by the

corporation.

* Coordinate the implementation of the ISO quality systems.

* Re-design and re-build locally all of the seven (7) existing program

tools procured by the customer overseas for the CT-20 program thus saving

the customer up to $ 500,000 per year, and saving us $ 100,000 for our

operations thru-

productivity gains, reduced down time and incomplete runs, and tool

maintenance.

* Provide the customers with multiple manufacturing options for a given

product, so as to show the merits and the related costs for each option,

and thus was able to bring in new business worth $ 20,000,000.

* Implemented cost saving of 15% in tooling ideas for the laser welded

products, including those for the A/H car.

* Conducted and completed several engineering change studies on both

major and minor steel stampings for manufacturing cost reductions and yield

savings thru altered part geometry.

* Provide regular customer service liaison for engineering and sales

activities to improve sales.

* Conduct manufacturing and product cost studies. Reduce manufacturing

costs by 10% through repetition and clear documentation of the process.

* Coordinate the implementation of the QS quality system.

* Study cycle times, and implement multiple solutions for part extraction

to improve the presses productivity by 7%.

* Studied the corporate quality structure, and then implemented a self-

directed and the 1st quality system in the corporation and thus reduced the

quality costs by 20%.

* Researched and studied the impact of HSLA coil steels on Tool Steels

and then Implemented the use of S-7 tool materials to the X-Car trailing

axle tools thus saving on by not to build back up tools - saved $ 60,000.

* Conducted joint studies on the fatigue properties of HSLA steels with

the customer for the requirements for break to shear ratios.

* Implemented a unique Heat Treatment process, and the development of

fixtures required to stress relieve and flatten the aluminum recording tape

discs.

* Implemented the SMED program to the Stamping Operations for reducing

the time of change over after each run by up to 50%.

* Implemented the maintenance of tooling thru out side supplier base thus

reducing the over all costs by $ 20,000/year.

* Implemented documentation of perishables for each tool and

manufacturing equipment and maintain a supply of spares to prevent un-

necessary setups during the runs and changeovers and thus increase in up

time by 10%.

* Created unique solutions in the use and manufacture of steel products

for Flint Metal Fabricating an OEM stamping facility, and thus help us

become their largest supplier with annual sales of up to $ 50M/yr.

* To order softer steel (within the specified specs as written) such as

1006 in place of 1008 without the Aluminum Killed Steel cost extra, when

1008 would definitely require that extra cost to permit the same

formability. Thus a savings of $.50/ cwt and up to $ 500,000 in total raw

materials cost per year.

* Implemented metallurgical testing procedures for draw-ability of raw

materials to save 10% in re-application costs.

* Study the weights and the minimum ordered thickness of incoming coils,

and then was able to reduce the minimum ordered thickness from each mill

based on their set points relationships, and thus reduce the cost of

incoming raw materials by 5%.

* Responsible for improving the productivity of Coil Steel batch

(sulphuric acid) pickling process by 10%.

* Institute incoming raw material receiving process to an actual measured

incoming weight against the manifest for improved cost structure by 5%.

* For the Stamping Tools, instituted "Ingoing" and "Outgoing" designation

for each tool so that staging & setup will be 100% correct each time and

every time.

* Implemented PM for the tools based on Hit to Hit for each run to get an

understanding of repair and sharpening costs thus reducing set up cost when

tools may not be released for manufacturing. Also implemented equipment

maintenance by manufacturing centers based on varied schedules in then 365

days of a year.

BOKARO STEEL LIMITED Aug 1972 - Aug 1974

As a Metallurgical Engineer, in-charge of quality, and shift operations in

the slab rolling mill of this multi million ton integrated steel mill.

Education, Professional Affiliations and Global Travel:

Bachelor of Engineering degree (5 year degree course) in Metallurgical

Engineering .

M.B.A.

Completed several primary Metallurgical Sciences, Tooling, and

Manufacturing System research and DOE assignments, and 6 Sigma

understanding.

As a member of the ASTM committee on sheet steel till Nov 2008. I was also

affiliated with SME, SAE, and ASM.

I have traveled to Germany, Spain, England, China, and Japan to manage

several OEM/other project assignments.

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