Continuous Improvement Engineer

Rutuja Raut

**** *** ***, *** ***, Seattle, WA **101 347-***-**** ******.****@***.***

EDUCATION

Harrisburg University, Harrisburg, PA June 2016-Present

Master of Science, Project Management GPA: 4.0

New York University Tandon School of Engineering, Brooklyn, NY Jan 2014

Master of Science, Industrial Engineering GPA: 3.23

Smt. Kashibai Navale College of Engineering, Pune, India Aug 2010

Bachelor of Engineering, Mechanical Engineering GPA: 3.3

WORK EXPERIENCE

Manufacturing Engineer, Harley-Davidson Motor Company, Kansas City, Missouri Jan 2017-Present

Lead process engineer and coordinator of supervisory activities for wheels and powertrain assembly.

In charge of creating standard work instructions, control plans, job safety risk assessment, ergonomic job measurement system, material layout, visual aids, process change notices and product deviation notices.

Lead and support model launch activities in wheel and powertrain assembly areas.

Achieve required changing throughput in real time and schedule fulfilment by using the EASE Line Balancing Module.

Develop PM schedules and TPM to improve overall equipment effectiveness of wheel auto balancer and other equipment for wheel and tire assembly.

Perform PPAPs /IPPAPs and PFMEA Analysis for build events, process verification and new product launch.

Implement processes to establish error proofing for workstations to improve manufacturing efficiency, first pass yield and reduction of defects. Provide technical support and troubleshooting for daily production activities.

Perform manufacturing systems audits for continuous improvement of assembly areas.

Continuous Improvement Engineer, Harley-Davidson Motor Company, Kansas City, Missouri Aug 2016-Dec 2016

Performed Yamazumi for analyzing assembly processes at workstations throughout the assembly line to identify and eliminate TIMWOOD wastes along with non-value added work and engage operators in following standard work.

Responsible for weekly 5S, Layered Process and Work Station Audits to identify issues in daily production activities and provide solutions for counter measures.

Performed Ergo Kaizen event to identify ergonomic risks as per standards of the plant throughout the fabrication department and developed solutions for design changes of racks and carts.

Coordinator of the Red Tag Area for the plant.

Identified and implemented continuous improvement initiatives on production lines to overcome frequent down time and quality issues.

Quality Assurance & Process Improvement Manager, Solidoodle LLC, Brooklyn, New York Mar 2014-Jan 2015

Implemented 5S system at each workstation, set boundary samples for assemblies and directed standard operating procedures to increase product quality and labor efficiency throughout the assembly lines. Managed and trained a workforce of 15-20 workers.

Documented production procedures to ensure standard assembly processes and timely updates.

Introduced quality inspection checklist throughout the production lines to install correct assembly parts, avoid defects and reworks.

By doing time & motion studies and using lean manufacturing techniques, eliminated non-value added activities, reduced wastes by 75 % and end-to-end production time by 45%. Installed necessary material handling systems.

Performed drop tests and failure analysis to imply safety designs of product and packaging, reduced shipping damages by 95%.

Created QA testing procedures and preventive maintenance schedule to ensure optimal equipment operation without costly downtime.

Process Engineer Intern, New York City Industries for the Blind, Brooklyn, New York Sept 2013-Dec 2013

Developed a detailed catalog of the products’ Bill of Materials (BOMs) with its manufacturing processes, machines used for each operation, demands and cycle times, logistics associated with shipments of the raw material and finished goods.

Performed detailed time & motion studies and product flow analysis to identify operational delays and causes of bottleneck. Implemented Value Stream Mapping and ABC analysis techniques to recommend a new layout which brought down the material travel time by 40%, cycle time of operation by 60% and reduced the work in progress by 35%.

Ergonomically redesigned the workspace without compromising the comfort of the visually impaired workers. Performed physical simulations to test the solutions.

Industrial Engineer Intern, D-Shape, Brooklyn, New York Oct 2012-June 2013

Worked on the facility planning and design of the 3D printer and printing manufacturing plant which consisted of looking out for new locations, inventory management techniques, facility systems and the material handling systems.

Designed various factory floor plans by studying possible assembly lines for the plant supporting safety programs and OSHA compliance.

TRAINING

ERP Systems: SAP Material Management and Production Planning Modules, SAP Testing (ECC 6.0) Apr 2015-May 2016

PROJECTS

Facility planning and designing of powdered laundry detergent plant Jan 2013-May 2013

Developed a preliminary design for a powdered laundry detergent plant using AutoCAD. The design included the site layout with the product flow, various processes, the machineries and the material handling equipment with their capacities.

Supply chain simulation Sept 2012-Dec 2012

Simulated a supply chain system of a laptop manufacturer who takes orders over the phone or via the internet. SIMPROCESS was used for the simulation and the statistical analysis of the output. Performed multiple replications to compare & determine its significance.

ACHIEVEMENTS & CERTIFICATIONS

Six Sigma Yellow Belt, Harley Davidson WCKC

The cycle time for a workstation exceeded the TAKT time, requiring 2 operators to complete the job. Performed Yamazumi to determine the value-added and non-value added steps in the assembly process and eliminate excessive motion and time. Used DMAIC to improve, optimize and standardize the process. Modified the workspace to limit motion, reducing the cycle time by 19% which was well below the TAKT time, making it a 1 operator job with 90% efficiency.

Ergo Kaizen

The kaizen event for fabrication department at Harley Davidson focused on ergonomics involved in material handling by the operators while lifting totes from racks and carts. Initiated the continuous improvement approach by Gemba walk and A3 problem solving. Used fishbone diagram and 5Whys to perform root cause analysis. Developed new designs for material handling systems to reduce the risk factors and long-term ergonomic fixes. Successfully reduced the EJMS NIOSH score from 2.2 to below 1, which is the standard acceptable threshold.

SKILLS AND ABILITIES

Continuous Improvement Tools and Techniques: Six Sigma, Lean, Root Cause Analysis, Fishbone Diagrams, SMED, SWOT, PDCA, DMAIC, DOE, SPC, TQM, TPM, Kaizen, Bottleneck Analysis, Just-In-Time, Visual Management, Process Problem Solving, Gemba walk.

Operating Systems and Software: MS Windows (7/Vista/XP/98/95), MS Office Suite, MS Project, MS Visio

Process Planning Tools: EASE, Yamazumi, ReliaSoft Xfmea, PDG, SHIELD, Powertrain Tracking System, Windchill

Design and Simulation Tools: AutoCAD, ANSYS, Solid Works, SIMPROCESS

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