Engineer Management Manager Manufacturing Project, Lean, supply chain

Muhammad Alam, PMP, SCPM

**** ********* ***., ******* **

Email: ********.****@*****.***

Phone No: 408-***-****, 510-***-****

Strengths:

• Highly motivated, responsible and hard-working lean manufacturing, supplier quality & Supply Chain Leader

• Excellent communication and interpersonal skills. Result oriented with effective team leadership quality

• Hands-on working experience of Toyota Production System, Fuel Cell Systems & Semi. Equipment mfg

• Expert in continuous process improvement, JIT, Kaizen, VE/VA, Lean Manufacturing, VSM & TPS

Experience

08/2006-Current

Oorja Protonics, Inc. Fremont, California

Director Of Operations

• Successfully launched three new model of Direct Methanol Fuel Cell for North American Market

• Setup of lean production line to mass produce reliable Fuel Cell increasing production capacity to 5 folds

• Setup of efficient Supply Chain including China, India and European suppliers with outsourcing of modules

• Reduction of BOM over 57% in 18 months through outsourcing, moldings and price negotiations

• Established a network of Methanol Suppliers throughout North America for a demand respond time of 24hrs

• Successfully implemented new ERP system to increase the efficiency of business processes

• Conducted sheet metal & plastic parts manufacturing process improvements to save time and cost

• In charge of Facility Setup, Safety, Leasing and HAZMAT Business Licenses from City and Local Authorities

• Responsible of various Industrial Patents in DMFC and innovator of Industrial trade-secrets of Fuel Cell

• Preparation of proposals along with National Labs and submission to Govt and DoD Green Energy Programs

• Directly reporting to CEO and or Board of Directors also presenting to VC and or Investors for Due Diligence.

Sr. Manager– Product Development Department

05/2005 – 06/2006

Adam Motor Company, Karachi, Pakistan

• Successfully designed and developed auto parts through local and foreign suppliers for car, jeep & truck.

• Conducted technical evaluations and selections of suppliers, qualification of their manufacturing processes and management of parts quality.

• Monitored issuance of technical data to the vendors including Engineering Change Notices & BOM updates.

• Monitored design finalization & control of the timeline of all development process of supplier parts.

New Product Introduction Industrial Engineer (NPIE)

06/2001 –04/2005

Applied Materials Inc., Santa Clara, CA. USA

• Worked as an NPI on transition of new products, from pilot to volume manufacturing.

• Completed manufacturing build on CPI WALD, WCVD, PPC Slim Cell, BTBASS & EPI Systems.

• Created sequence of events (SOE)/assembly procedures of newly designed products for volume manufacturing various product business groups within organization.

• Conducted digital design mockups and design reviews to build quality in the product from design phase.

• Perform DFA analysis, tact time-study; develop product sync, lean line layout design and PFME analysis.

• Conducted Safety Audit for the department on biweekly basis and present quarterly reports to mgmt.

• Conducted cost analysis for US OEM suppliers setting manufacturing site in industrial parks in low cost region of ASEAN countries.

Project Engineer (one year) 1999-2000

12/1996 – 09/2000

Toyota Motor Corporation (TMC), Toyota-city, Japan

• Handpicked from a group of engineers to take a lead role in developing Corolla model for a timely launch.

• Prepared localization strategy and schedule of new Toyota Corolla to be introduced in the year 2002.

• Negotiated designs and processes for localization of parts with each Corolla design groups at TMC.

• Prepared component & sub-component list of new Corolla including design and development history, estimated development time, costs, process & design attributes of each part.

Product Development Engineer

12/1996 – 09/2000

Toyota, Indus Motor Company, Karachi, Pakistan

• Selected new suppliers and candidate parts of Corolla & Tacoma for future development.

• Implemented quality checks and provided feedback during the development process of parts.

• Designed and implemented Engineering Changes & modifications.

• Performed Value Engineering and Value Analysis on under development and developed parts.

• Provided technical support for the development of built-in-quality processes using Kaizen & TPS tools.

• Scheduled and monitored the development time of each part from suppliers.

• Performed supplier quality audits for quality assurance of incoming parts.

• Prepared Quality Documents for ISO-9000 Certification.

• Analyzed supplier quotations. Estimated the cost of parts & negotiated the price with suppliers.

• Prepared approval papers for Government for the Localization Plan of future candidate parts.

Education

Stanford Certified Project Manager (SCPM)

Stanford University, California, United States

PMI-Project Management Institute

Project Management Professional (PMP)

MS in Industrial & Systems Engineering, Aug 2002

San Jose State University, California, United States

BS in Mechanical Engineering, June 1996

NED University of Eng. & Tech., Karachi, Pakistan

Professional Training & Conferences Attended:

• Lead Auditor ISO 9001: Certified Lead Auditor ISO 9001 & RABQSA Certified (including ISO-13485 for Medical Devices)

• CPIM (Certified Professional Inventory Management): Modules completed MPR, ECO, SMR

• Applied Materials Inc.: Equipment Reliability, Failure Modes and Effects Analysis(PFMEA), Design for Assembly (DFA), Design for Cost Management (DFCM), DFx Design for Manufacturability and Producibilty (DFMP), Lean Production, ISO 9001(2000) Concepts and Updates, Engineering Drawing and GDT Level 1, Workmanship Standards Application, Finance for Operations, Ergonomics, Behavioral Interviews, Presentation Skills and, Red Dot 4 Safety Training from Applied Materials Inc.

• Toyota Motor Corp., Japan: One-Year Diploma in Vehicle Production Localization from Toyota Motor Corporation, Toyota-city, Japan. 1999

• Three months Japanese Language diploma from ILO org., Chiba, Japan., 1999

• Silicon Valley Manufacturing Roundtable, San Jose, CA, 2012 and 2013

• Simulation Solution conference 2002, IIE, San Diego, CA.

• Annual SemiCon West conference Sanfrancisco-2001 & 03

Languages:

Fluent in English, Urdu, Hindi and Japanese ( know how)

Academic Course Work:

Organizational Analysis & Management

Simulation (Manufacturing Ops)

Quality Assurance and Reliability

Operations Research

Accounting for Business Decision

Production and Operations Management

Industrial & Systems Engineering

Design Of Experiments

Social Political & Legal Environment of Business

Macroeconomics Theory & Policy

Computer Skills:

Expandable ® (ERP), AMPL, Pro-Model (Simulations), Spreadsheets, Access, Excel, Word, Power Point, AutoCAD, VisView (Digital MockUp), Ms Project, working knowledge of SolidWorks, Unigraphics & 3D Printing

Affiliations:

• PMI- Project Management Institute- PMP

• APICS- Association of Operations Management- CPIM

• Recipient of National Science Foundation (NSF) stipend from SJSU Physics department in year 2001.

• BSA-Boy Scouts of America

Work Authorization

US Citizen

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