Lean Manufacturing Management

Vardhan Ijare (ASQ-CSSGB)

Dearborn, MI-***** ********@*****.*** Ph.: 313-***-****

EDUCATION

University of Michigan - Dearborn, MI.

Aug 2016 - Present

MS in Industrial and Systems Manufacturing Engineering

GPA: 3.4

Coursework: Quantitative Methods and Quality Analysis, Design and Analysis of Experiments, Big Data analytics & Visualization, Business Process Integration-ERP, Total Quality Management, Production and Operations Management, Human Factors and Ergonomics, Program Budget and Cost Estimation, and Digital Manufacturing.

KLS Gogte Institute of Technology, Belgaum, India - 590008

Jun 2011 – Jul 2015

Bachelor’s in Mechanical Engineering

TECHNICAL SKILLS

Statistical Process Control, QFD, FMEA, 5S,

Project Management, Lean Canvas, Kaizen,DMAIC, SWOT Analysis, GD&T, Parametric Cost Estimation, Production planning & Forecasting.

SOFTWARE SKILLS

Solid Edge v19, Master Cam X8, ANSYS10, Minitab 2017, Jack Simulation, Microsoft Office, SAP, Tableau.

WORK EXPERIENCE

Quality Analyst and Chief Technical Lead, @ Zepnox Pvt Ltd, India. Aug 2015 – Aug 2016

Conducted Surveys and Data-Mining for specific customer requirements as per the Onsite & Client feedbacks and developed an application module which was valued at INR 1000000 ($14,000)

Developed product and process based solutions in Education Domain by addressing Existing Market problems, eventually leading towards the recognition of the Start-up.

Taught and Implemented quality/project management tools and principles such as PDCA, SWOT, Kaizen, 5S, Poka-Yoke, PDPC, Kano Model, QFD, to establish a firm foundation for the team and company from initial stages of process and product development, while promoting employee involvement and company performance

Initiated Marketing/Advertising campaigns by addressing various locations with specific objectives and providing marketing solutions through data-interpretation and visualisation on Microsoft Excel. This helped in supplying location specific content to a variety of states, helping the firm establish branches and tie-up across India

Set-up various Incubation centres at Academic Institutes to ensure strong support for upcoming and talented engineers. This helped to firm to gain potential network base, recognition from highly experienced Academic Advisors, and each incubation centre was valued at INR 150000 ($2200)

Rendered support to the application modules in a contextual premise under the designing wing and understanding the demographic distribution in different territories across the country, through product/process development methods such as Lean Canvas, while extensively studying and achieving an upper edge over intellectual property rights

Bagged an investment of INR 1200000 ($17000), to initiate the production and development of Air-Fi Project (a product which provides exclusive infotainment, Free, and Wirelessly)

Projects and Achievements

Air-Fi

Delivered free and exclusive academic data/syllabus for students across 4 schools and 7 free hubs throughout various & remote locations of India.

Facilitated the development team with Budget Estimation and Cost-saving models.

Extensively worked on the packaging, design and front end of the product and content.

Installed products into public/government transport systems which aims at providing Infotainment of locations.

Bagged installation of Air-Fi at residential communities to produce 200+ units.

School Application module

Created the syllabus for Extra-Curricular course to be implemented in schools across the state of Rajasthan.

Data-mining through survey, existing records, and graphical visualisation of the data-sets.

Sold the service at an amount of INR 800000 ($10000), to private sector chain of schools.

Industrial Engineering Intern, @ Bharat Fritz Werner Ltd., Bangalore, India Jan 2014- Feb 2014

Received training on assembly lines of Horizontal Machining Centre (HMC) like TMC 1000,

TMC 1250 & MPH 650 based on automated assembly systems.

Assembled Numerically Controlled High Speed Turning Centre machine and performed calibration tests such as backlash test, Axis calibration, Circular Interpolation etc.

Lead the marketing team and provided engineering support to the customers and clients at various manufacturing & forming exhibitions such as IMTEX-Bangalore(India) in 2014 & 2015.

Associate Production Engineer Jan 2012-Jan 2014

I was part of constructing the Quality Manual conforming to ISO 9001:2015 and implementing PDCA, Process Interaction Map, SWOT analysis, 5S, Customer feedbacks, and documented Quality Management System for process improvements throughout the plant.

Experience in calibration for performance evaluation of CNC machines in accordance with the standards of ISO 9001, and performed various tests like Backlash, Circular Interpolation for accuracy, determination of the setting accuracy on the diagonals in the working area, and determination of the spindle run accuracy during rotation.

Inspected dimension and other attributes of manufactured products for conformance with internal quality standards, and created worker schedules.

Facilitated the Quality Department through successful adoption of Lean Manufacturing Practices; ISO-9001:2015 registration; cost and scrap reduction; Budgeting-cost estimation, and process/product development through DFSS methodology.

Maintained and developed current relations with suppliers/vendors, through Sales Engineer Feedbacks, Client Survey, Implementing Lean Manufacturing process tools, and by presenting Total Quality Management workshops to various

Analysis of heavy component casting, strain hardening and optimization of assembly line.

Received training on Cast Iron & SGI casting/moulding and plotting Value Stream Mapping.

GRADUATE PROJECTS

Prototype Portable Water Filter

3D printed a patentable and portable water filter.

Created an effective business model for manufacturing under ISO standards.

Tools used: QFD, FMEA, Creo 3.0(CAD), Lean Canvas, Kano Model, Microsoft Excel, Fault Tree, Cause Effect Analysis.

Results:

oScaled up production to 1000000 units.

oGenerated a fully functional Cost-Benefit Analysis.

oShowcased a prototype model.

Scrap Reduction in Friction Disk Assembly Process

Measured and recognized the potential noise & waste reduction parameters in the assembly line.

Calculated the outcome by using quantitative analysis and implemented solution.

Tools used: DMAIC, VSM, FMEA, MINITAB, Gage R&R, Process Capability (Cp-Cpk), Null Hypothesis.

Results:

oVSM proved TACT time was high at Per-stick stage.

oPareto analysis demonstrated the contribution towards scrap, and scrap breakdown.

oGage was proved acceptable.

oGluing Line process wasn’t capable and variation existed. Cp = 0.96

Case Study on Inventory Management of Apple Inc

Carried out Data Mining, Forecasting and Trend Analysis of Apple products.

Benchmarked and studied the Supply Chain and Logistics for product transportation.

Tools used: Time Series Forecasting, SWOT, EOQ, Break Even Point.

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