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Six Sigma Engineer

Location:
Frisco, Texas, 75035, United States
Posted:
May 23, 2010

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Yusuf "******" *****

**** ********* ****

Frisco, TX 75035

972.***.**** (Mobile)

******@*******.***

Lean Six Sigma Skills

Lean Manufacturing: Pareto Analyses, Value Stream Mapping, Process Flow

Analyses, Time Studies, 5-Why Analyses, Line Balancing, Kaizen Events, 5S,

SMED, Poka-Yoke, Kanban, etc

Six Sigma: DMAIC, Fishbone Diagrams, Z-tests, t-tests, Gauge R&R Studies,

ANOVA, Individual Distribution Identification, Capability Analyses, DOEs,

SPC, etc

Significant Accomplishments

. Reduction of top 80% defects by up to 70%

. Up to 53% floor space reduction, 116% productivity improvement & 44%

headcount reduction

. Up to $759,000 annual cost savings achieved per Kaizen event / Lean

project

. A total of over $2,100,000 annual cost savings have been achieved to

date through reductions of the 7 deadly wastes

Professional Work Experience

Continuous Improvement Manager, May 2010 - Present

. Trained in Six Sigma Black Belt

. Responsible for managing the following:

o Company-wide labor, material, and overhead cost savings plan

and process

o All Kaizen and Lean Manufacturing planning and associated

project work

o Capital planning process and justification of projects

o New Product Implementation Committee

o Product margin analysis and improvement

o Facility and space planning

Manufacturing Engineering Manager, July 2009 - May 2010

Lead Manufacturing Engineer, July 2008 - July 2009

Rochester Gauges

Dallas, TX

. Develop, prioritize & manage Mfg E projects to continuously improve

factory efficiency & productivity

. Oversee manufacturing processes & lead the Mfg E team to achieve

departmental goals

. Perform cost-benefit analyses and make vs. buy analyses and present

proposals

. Lead & participate in daily Gemba walks throughout factory & work with

cross-functional team to prioritize and solve issues discovered thru

Gemba walks

. Drive, lead & participate in Kaizen events and Lean projects using

Lean & Six Sigma tools

. Lead and participate in cross-functional team meetings to perform

DFMEA, PFMEA and develop control plans for new or redesigned products

. Perform other Mfg E duties as needed as described below:

Manufacturing Engineer, March 2005 - July 2008

Rochester Gauges

Dallas, TX

. Trained in Lean Manufacturing

. Participated in Kaizen / continuous improvement events & Lean projects

using Lean & Six Sigma tools

. Designed & optimized production systems for new & existing products to

establish balanced continuous flow and maximize efficiency while

improving ergonomics & safety

. Re/designed fixtures to poka-yoke / failsafe processes and improve

product quality & productivity

. Established visual metrics to monitor hourly throughput and capture

causes of downtime to allow quick responses to issues that prevented

work cells from achieving production goals

. Implemented kanban / pull system to effectively and efficiently

replenish materials in work cells

. Participated in cross-functional team meetings to perform DFMEA,

PFMEA and develop control plans for new or redesigned products

. Performed PPAP or validation for new or improved design or process

. Analyzed production issues to discover root causes and provide &

implement solutions, reducing scrap & production costs and improving

productivity using Lean & Six Sigma tools

Quality Assurance Co-op, January - August 2003

Maytag Appliances

Amana, IA

. Trained in Lean Manufacturing and Six Sigma Green Belt

. Participated in Kaizen / continuous improvement events

. Conducted gauge R&R studies, developed & analyzed control charts, and

conducted capability studies

. Improved production methods and re/designed fixtures/tooling,

resulting in improvement in productivity

Industrial Engineering Intern, June - December 2002

Firestone Agricultural Tire Division

Des Moines, IA

. Developed automations resulting in reduction of ergonomic issues &

production costs, improvement in product quality, and increase in

productivity

. Conducted time studies, developed process flowcharts & performed line

balancing to improve workload distribution and reduce bottleneck &

cycle time

. Designed AutoCAD layouts of proposed equipment modifications

. Performed cost-benefit analyses & calculated ROI & payback period to

justify proposals

Education

B.S., Industrial Engineering, Iowa State University, Dec 2004

GPA: 3.27/4.00

Computer Skills

MS Windows, MS Dynamics AX, MS Outlook, MS Project, MS Access, MS Excel

including PivotTable/Chart Analyses & Macro Programming, MS PowerPoint, MS

Word, MS Visio, AutoCAD, SolidWorks, Minitab

Awards

Outstanding Industrial Engineering Design Award (1st Place), Spring 2004



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