MAHESH DALVI

**** ****** ***** *****, ********, OH 43560

Home 419-***-**** Cell 586-***-**** abnwm3@r.postjobfree.com

SUMMARY

Over 10 years of manufacturing and process experience in production related industries.

Self-Motivated; able to work independently and in teams; handled multiple projects while paying

attention to details. Achieved organizational goals using leadership; project management and

supervisory skills.

Expertise in MODAPTS, AutoCAD 2008, Visio, Microsoft Office (Word, Excel, PowerPoint, Project

and Access).

Good communication and interpersonal skills.

EDUCATION

M.S., Industrial and Management Engineering with emphasis on Manufacturing Systems, and

Quality Control, GPA: 3.41/4.00, Montana State University, Bozeman, Montana, August 1998 – May

2000

B.S., Production Engineering, GPA: 3.5/4.00, University of Bombay, India, June 1989 – June 1993

CERTIFICATIONS

Certified in MODAPTS by International MODAPTS Association.

Certified in Six Sigma Green Belt.

Certified in Lean Manufacturing

Certified in VIA, Productivity Improvement Through Time Study® and VIA, World Class

Manufacturing®

PROFESSIONAL EXPERIENCE

Consultant at Production Modeling Corporation (PMC), Dearborn, MI [April 2009 – Present]

Client : Chrysler (JEEP) - Toledo Supplier Park, Toledo, OH

Role : Team Industrial Engineer / Production Supervisor

Team Size : 4

Description :

Provide production support in the form of Production Supervisor for Door Line Assembly

Assist in preparing for TUV audit by validating standardized work instructions at each job station

across all shifts

Validate sequence of elements in work instructions with actual sequence of work performed and

standardize sequence of operations across all shifts

Develop detailed plans for continuous improvement and validate plans with Team Leaders and

Area Managers

Lead Industrial Engineer at IET Inc., Toledo, Ohio [August 2000 – April 2009]

1. Client : Philip Morris, Richmond, VA

Role : Team Industrial Engineer

Team Size : 4

Description :

Conducted sequential work sampling of the KDF filter making operation to determine the feasibility of

one operator running three machines instead of two machines with new automatic testing equipment

in place

Conducted manning analysis of the KDF filter making operation to justify the purchase of new

automatic bobbin changer and determine the overall impact on productivity

2. Client : Tru Logistics, Fredericksburg, VA

Role : Supply Chain Analyst

Team Size : 2

Description :

Evaluated the existing supply chain network for ‘Therma-Tru’ brand packaged doors to minimize

customer returns, reduce inventory costs and minimize material costs

Worked across regional distribution centers with shipping companies in various locations in United

States to optimize the transportation system resulting in reduced handling of doors

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Proposed and implemented new packaging solutions which reduced freight damage and improved

customer service for Tru Logistics and it’s suppliers

Developed and implemented Process FMEA to root cause and control customer returns due to

freight damage, design defects and manufacturing defects

3. Client : Dana Holding Corporation, Lugoff, SC

Role : Time Study Analyst / Lean Manufacturing Engineer

Team Size : 2

Description :

Conducted continuous time studies and analyzed results for final assembly of Traditional and

Hercules brand rear axles for off-highway products

Implemented 5S and lean manufacturing techniques to reduce waste and improved cycle time by

35%

4. Client : Chrysler (JEEP) - Toledo North Assembly Plant, Toledo, OH

Role : Team Industrial Engineer

Team Size : 5

Description :

Developed and implemented detailed productivity improvement plans. Worked closely with all

departments to implement the plans (Required to Run Task). Average productivity improvement

savings per year - $700,000

Performed line balancing and waste removal using current state line observations, moving line

charts, PDCA’s and Yamazumi (Chip) charts. Achieved line balancing target of 95% efficiency and

85% utilization.

Worked with the union to resolve any IE related and production floor issues

Lead team of maintenance, IT, safety, production control, ergonomics, production and union team

leaders / stewards in implementing Work Station Optimization improvements

Provided IE support during pilot run and new model launch for Dodge Nitro and Redesigned Jeep

Liberty

Participated in problem solving teams during launch to resolve part / build issues

Checked station readiness for new model launch

Conducted meetings with Plant Vehicle Engineering Group, Advanced Manufacturing Engineering

Group and Suppliers over Process / Product Changes

Updated Process Sheets and Parts Information in Automated Manufacturing Planning System

Converted all Chrysler Standard Times on man assignments to MODAPTS times. Utilized MODAPTS

studies to balance workstations

Worked with Production Advisors to meet weekly and monthly Station Direct Run Loss (SDRL) goals

Handled day-to-day IE issues on the floor – Responsible for Trim and Door Line

5. Client : GM Powertrain, Romulus, MI

Role : Process Engineer

Team Size : 3

Description :

Designed and implemented gauge tables with color coding resulting in standardized gauging process

for V6 and V8 Block Line machining

The standardized gauge table design was set as benchmark and implemented at other GM facilities

in North America

Updated Process FMEA for 2003 4.3 liter V6 Engine Assembly

Updated layouts using AutoCAD 2000 to accommodate new marine engine production for 2003 4.3

liter V6 Engine Assembly

Developed Job Instructions, Visual Aids and Error Proofing documents for 2003 4.3 liter V6 Engine

Assembly

Conducted Delay Studies and analyzed results in the form of Pareto Charts at V8 Engine Headline

Assembly

6. Client : Stageright Corporation, Clare, MI

Role : Lean Manufacturing Engineer

Team Size : 2

Description :

Provided objective engineering analysis of process and material flow, storage requirements and

lead-time reduction opportunities for the staging and football equipment manufacturer

Documented current and future state process flow using Value Stream Mapping

Proposed one-piece flow of material and Kan-Ban Pull System thereby reducing work-in-process

inventory by 50%

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Proposed facility layouts that promoted smooth material flow and efficient space utilization in a Lean

Manufacturing Environment

7. Client : Chemical Specialties Inc., Harrisburg, NC

Role : Material Flow and Layout Engineer

Team Size : 1

Description :

Re-routed overall traffic flow, reviewed scheduling and traffic routes of tanker trailers in and out of

the facility for optimal flow

Designed tanker parking lot and plant layout including tank farm loading/unloading

Conducted material flow analysis to find out daily manning at 8 hours/shift/person

8. Client : Collins and Aikman, Williamston, MI

Role : Methods Engineer

Team Size : 3

Description :

Developed a strategic manufacturing plan for the automotive headrest and armrest supplier, by

analyzing data collected by conducting time studies, work sampling, storage and capacity

analysis

Proposed layouts for possible expansion scenarios using AutoCAD 2000

9. Client : Filcon, Clare, MI

Role : Project Engineer

Team Size : 4

Description :

Analyzed manufacturing operations and developed proposed layouts for the food products packaging

company

Designed manufacturing system to support the anticipated business volume with minimal labor cost

10. Client : American Axle and Manufacturing, Three Rivers, MI

Role : Facilities and Layout Engineer

Team Size : 2

Description :

Implemented Plant Layout Design Project using AutoCAD 2000 for complete manufacturing facility

of 11.5” Rear Axle Machining and Assembly for GM Trucks

Designed new layout considering manpower allocation for 3 shifts, provision for scrap and rework

disposal including chip collection system design, overhead bridge rails, raw materials and WIP space

allocation according to daily volume requirements and office space design

11. Client : Mannesmann VDO, Auburn, Indiana

Role : Time Study Analyst

Team Size : 4

Description :

Conducted Time Studies and Delay Studies and reduced the overall cycle time by 40% for Ford

Motor Company’s Airbag PCB manufacturing facility

Analyzed root cause of individual machine processing time delays and balanced the line thereby

reducing cycle time for bottleneck operation

12. Client : Kraft Foods, Kirksville, MO

Role : Project Engineer

Team Size : 4

Description :

Worked on Continuous Improvement Project involving employee training and tracking equipment

downtime to increase Overall Equipment Effectiveness (OEE)

Design Engineer at Graphic Angles, Mumbai, India [October, 1996-April, 1998]

Team Size : 10

Description :

Analyzed design failures using Design FMEA principles and recommended actions to improve safety

and reliability of HVAC system design for diamond trading facility

Interpreted layouts and superimposed ducting and piping layouts on basic drawing taking into

account all ceiling and floor obstructions involved

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Trainee Engineer at Damodar’s El-Mech Services P. Ltd., Mumbai, India [July, 1994-September, 1996]

Team Size : 4

Description :

Supervised daily stores, inventory and production functions of Automotive Repairs Department.

Handled customer issues and actively involved in trouble shooting and implementing corrective

actions.

Process Trainee at The Tata Electric Companies, Mumbai, India [April, 1998–June, 1998]

Team Size : 6

Description :

Monitored fuel consumption patterns in Operations and Plant Betterment Department

Studied fuel consumption patterns for last 5 years and established knowledge base for forecasting

AWARDS AND RECOGNITION

Awarded “MOST DYNAMIC PROJECT TEAM”, IET INC, 2003

Awarded “MOST DYNAMIC PROJECT TEAM”, IET INC, 2006

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