Senior manufacturing Engineer

MADHURESH CHOUDHARY

Greenville, SC/ ***********@*****.*** / 713-***-****

Education:

Master of Science, Industrial Engineering – University of Houston - Main, Texas Jan 2008 – Dec 2009 Bachelor of Engineering, Mechanical Engineering – University of Mumbai, India Aug 2002 – Jun 2006 Work History:

Industrial Engineer, Lear Corporation – Duncan, SC Oct 2012 – Present 1. Warehouse Project ($500K+): Planned, Managed with coordination with various teams to successfully execute moving the equipment, racking, material and setting up at new location. Created project task and timelines and kept track of spending comparing the budget. Lead the maintenance team for rack install and electrical requirement for operations. Analyzed current v/s future state for layout for material slotting and indirect labor.

2. Conveyor Projects (2016 - $1.2M+ & 2014 - $1.1M+): Analyzed and presented the business case for replacing the existing conveyor/ assembly line with high speed conveyor to meet increased demand and to integrate the new product and future expansion. Coordinated with corporate team for layout for quoting and vendor selection. Created project tracking for vendors, contractors and maintenance for successful execution. Coordinate with corporate and plant IT & MES team for new system integration. 3. Capacity Analysis Projects (2017 - $1.3M+ & 2016 - $700K+): Analyzed customer demand to determine the capacity for each product line, warehouse space and shipping area. Presented the investment required to facilitate the plant to deliver the required demand for Just in time. Line rebalancing to achieve target efficiency. Coordinate with corporate team to present various projects and the return on investment. Determined the most cost efficient overtime/number of shifts ratio to meet customer JIT overtime.

4. Continuous Improvement Projects: Lead and train operators with multiple projects including line rearrangement with new concept flow for sub assembly, line side material presentation, sequencing operation to reduce non value added time. Equipment and Labor analysis to determine elements for improvement. Downtime tracking to identify areas for kaizen events. 5. Lean Warehousing Project: Coordinated with plant and corporate teams and Conducted Business case to analyze headcount required to run and acquire the 3PL operated warehouse along with equipment and material required for lean warehousing. Implemented efficient material handler utilization using Maxi-Most for part delivery. Analyzed the existing delivery from supplier and presented and executed the proposed delivery time and date for truck scheduling. 6. Inventory & Logistic Projects: Analyzed the warehouse space required based on PFEP, shipping frequency and standard pack for footprint in the warehouse. Presented the business case from operation and management for cost saving.

7. Automation Projects: Data analysis and time study to present Automation on the shipping load/ unload for efficient finished goods flow to customer racks and turn round time for empty pallets. Risk analysis on equipment to determine the areas for additional automated shuttle system. 8. New Product Introduction: Coordinate with Lead engineers from different departments; Design, Reliability & Testing and validate Design for Assembly/Manufacturability (PFMEA) of new product. Labor analysis based on design to submit for costing/sales team. Acquire tooling and assembly fixtures for poke-yoke and ease of assembly following Good manufacturing practices. Analyze packaging requirements by conducting Stress test for durability of parts based on packaging container and size of in-coming assembly parts. Cost reduction projects for Just in time delivery of material department to prepare Plan for Every Part (PFEP)

MADHURESH CHOUDHARY

Greenville, SC/ ***********@*****.*** / 713-***-**** 9. Day to day Responsibilities:

Integrate and troubleshoot Manufacturing Execution Systems (MES) for new and existing product

Integrate vision system, scanning, GO-NOGO fixture, PLC integration for automation and process control, Torque DC for safety critical (FMVSS)

KPI based on downtime reporting, accounting and throughput to determine the areas of improvement based on equipment, process, material or layout (Continuous Improvement Projects)

Coordinate with Continuous Improvement team to conduct weekly 5S and 7 waste audits for maintenance, production to determine key performance areas

Implement Total Preventive maintenance for each area

Coordinate with corporate team for Best practice implementation

Coordinate with key team members for implementing Automated material delivery project

Work with Maintenance team for project assignment and completion

Execute plan for shutdown for major/ minor projects for improvement

Make plant/ line drawing for effective process flow and material spaghetti diagram

Work with CI and Maintenance team for efficient station layout based on process Manufacturing Engineer, John Deere – Waterloo, IA Feb 2011 – Sept 2012

Identify and address root cause for manufacturability issues involving process change

Lead the line design process for an assembly line zone (Cab assembly) including value stream and process mapping, cycle time and capacity, sequence of events and graphical work instructions, layout, quality planning, material planning and implementation, optimizing NVA(Non value added) process

Plan and manage small to medium scale projects associated with facilities and equipment installations to support program build schedules (durability thru start of production)

Identify and implement mistake proofing to address root cause for orientation and assembly issues parts for critical assembly of hydraulic, steering, windshield

Develop work station layouts, material and tool presentations to support cost reduction, quality, safety, ergonomic, material flow and visual factory improvements

Execute machine acquisition, tool and fixture requirement for scheduled build events

Work with Tool design team for fixture and tool design and build for quality and process improvement high risk assembly complications – hydraulic hoses and fittings orientation for brake and steering valves to eliminate rubs and leaks, tool for lifting devices for assembly automation

Lead the Engineering Change Process correcting BOM inaccuracy using SAP –PP&MM

Lead preventative maintenance, perform 5S audit, identify areas for Non-conforming material Manufacturing Process Engineer, India Tube Mills Pvt. Ltd. – Mumbai, India Jun 2007 – Nov 2007

Lead projects on fabrication of process column, heat exchanger and storage tank for refinery plants and on site fabrication for setup

Conducted time and motion study analysis for various work-station & product and performed capacity v/s demand analysis while maintaining Good Manufacturing Practices

Identified the value added and non-value added steps to streamline manufacturing processes

Proposed overall overhead cost reduction by 25% with 15% total cycle time reduction MADHURESH CHOUDHARY

Greenville, SC/ ***********@*****.*** / 713-***-**** Certification

Maxi-MOST Jun 2016

APQP & PPAP, 8D certification Feb 2015

MOST Certification Sept 2013

Industrial Engineering & Motion Time Measurement (MTM) Certification Aug 2011 Root cause analysis, PFMEA & Mistake proofing certification Mar 2011 Lean Manufacturing & Value Stream Mapping Workshop Certification Apr 2010 Six Sigma Green belt workshop certification Nov 2009 Skills

Manufacturing Execution System: LPS (Lear), Ujigami Rockwell Automation: RS Classic 500, 5000, Micro Logix, Compact Logix, Control Logix, Device net, Panel-view Process control Systems: Keyence, Matrox, Cognex, Presence Plus, Banner, SICK, Pick to light DC Torque Tools: Atlas Tool Talks, Stanley Works, Gesipa/Taurus Rivet Tools Software: Microsoft-Office-Access, Microsoft Vis view, E-VSM, Arena Simulation 14.5, AutoCAD 2016, ProE 3.0, CATIA 5.0, SAP-PP & MM, W-Planner, Teamcenter, DEWE-SOFT

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