Engineer Process

PANKAJ KHAIRNAR

****, ***** ***** *****, *********, TX-76011. Mobile: 806-***-**** Email ID: ***********@*****.*** EDUCATION:

- Texas Tech University- Lubbock, Texas, USA Graduated: May 2016 Master of Science, Industrial Engineering (GPA 3.6)

- Pune University- Pune Maharashtra, India Graduated: May 2012 Bachelor of Science, Production Engineering (First class with Distinction) WORK EXPERIENCE:

NCH Corporation- RPG (Retail Products Group) – Dallas, TX March 2016- Present Process Engineer:

Lean Manufacturing, Process Improvement & Quality Control

- Improved OEE by 4.7% by implementing TPM on the shop floor and using structured problem solving techniques.

- Initiated the project for Root Cause Analysis (Fish Bone Diagram) to take robust and sustainable CAPA (Corrective Action Preventive Action) approach to minimize the waste. So far reduced by 1.2% (Roughly 3240 units/shit).

- Created a thorough database to track production process improvements to drive quality, uptime, and operator performance to ensure demand attainment. (MS Excel-Lookup, pivot table etc.)

- Introduced the WINSPC (Statistical Process Control) tool and its benefits to track the product/process performance and process capability.

- Trained the QC auditors on maintaining the daily production information and analyzed the results.

- Identified the key factors responsible for adversely affecting the daily production activities and eliminated them.

- Revised the product dimensions and tolerances for the Visual Inspection System and monitored the system daily

- Improved the CpK (Process capability Index) from 0.82 to 1.56 (4 sigma) and maintained PpK (Product Performance Index at 1.35.

- Reduced the customer complaints by 40%, and raised the durability of the process by coordinating FMEA (Failure Mode Effect Analysis), frequent reviews on product design specifications and tolerances.

- Executed SMED (Single-minute Exchange of Die), standardized the process and reduced machine changeover time by 65% and waste by 90% during the changeover process.

- Trained the operators by developing the changeover manuals and SOP’s (Standard Operating procedure) and maintain the training matrix for efficient startups.

- Created all the documentation such as Check sheets, standard work, job cards and SOP’s for audit purposes.

- Prepared advanced troubleshooting manuals and trained the operators/supervisors/line mechanics to reduce Corrective maintenance time by 45%.

- Implemented 5s to maintain the order, increase the efficiency and safety on the production floor.

- Assisted in making the BOM’s (Bill of Material) for all the products.

- Successfully introduced manufacturing procedures and design modifications for the machine for 6 new products & implemented them in the daily production.

Ram Krishna Industries - Pune, Maharashtra Jan 2013 – August 2013 Process Engineer

- Developed solutions to production problems related to materials, machinery and processes.

- Successfully handled the Design, Development and Installation phase of engineering projects. Introduced and implemented cost-effective methods of manufacturing.

- Defined and maintained the process standards and introduced SOP’s for the existing and new processes.

- Measured variances to standards, identified out-of-control variances, investigated causes and suggested solutions by analyzing and maintaining the process quality.

- Introduced Visual indicators and informative documents (Templates, Performance Graphs) to improve the knowledge base of the operators increasing the production efficiency.

- SMED (Single Minute Exchange of Die) is introduced on the production floor. By designing the new Jig and fixture, changeover time is reduced by 40%.

- Implemented 5s by co-coordinating 20-25 draftsmen to maintain the efficiency, quality and performance.

- Improved process capability and production volume while maintaining and improving quality standards.

- Reduced the lead time of the process by 28% by using TPM and KAIZEN principles during the production.

- Maintained reliable and quality manufacturing practices by using APQP (Advance Product Quality planning).

- Collected, recorded, and transcribed data for Process Validation of the tools and equipment. PANKAJ KHAIRNAR

1612, Ridge Haven Drive, Arlington, TX-76011. Mobile: 806-***-**** Email ID: ***********@*****.*** Kailash Vahan Udyog Ltd.”, Pune, Maharashtra. Sep 2012 – Dec 2012 Quality Engineer

- Overall responsibility of Quality assurance and documentation.

- Attended customer audits and reviewed customer complaints and responded within 24hrs.

- Calibrated all the Jig/Fix/Gauges required in process and maintained validated list. Gabriel India Ltd - Pune, Maharashtra. Jan 2012 – July 2012 Manufacturing Process Engineer

Project: Streamlining the Zigzag Flow and Line Balancing.

- Defined hourly outputs (Cycle Time Study) for all the manufacturing cells depending upon Takt time and prepared Standardized Work Charts according to line balancing and executed Value Stream Mapping (VSM).

- Prepared Man-Machine charts, performed REBA Analysis for ergonomic aspects and streamlined the zigzag flows.

- Analyzed the downtimes in the peripheral assembly processes in cellular manufacturing units.

- Initiated the improvement projects for reducing inventory (i.e. reducing inventory and material handling costs).

- Standardization of process by monitoring and analysis through Process capability (Cp) and capability index (CpK). Results: - Reduced no of operators by 2/shift and streamlined the process flow.

- Operator performance improved by 17%, thus improving the Overall Equipment Efficiency (OEE).

- Increased production by 100 units/shift, and material shortage time was eliminated completely. Cadbury India Ltd – Pune, Maharashtra.

Manufacturing Process Engineer July 2010 – Dec 2010 Project: T-Reactor Cycle Time Reduction

- Studied and Monitored the T Reactor operating system and did Cycle Time Study.

- Prepared Preventive Maintenance schedule for the system. Results: After taking some corrective actions, batch timing of T Rector reduced by 25 min/batch. Technical Skills sets:

Certification: Six Sigma Green Belt

Operating Systems: OS X, Microsoft Windows XP/07/08/10 Hands on Experience: Microsoft Office (Word, Excel & PowerPoint), Win SPC, Minitab, Exact MAX (ERP), Turbo CAD Deluxe 2017, Microsoft Access.

Design Courses: AutoCAD, UNI GRAPHICS (UG), PRO-E Wildfire 4.0., Arena (Simulation) Awards / Honors / Achievements Paper Presentation:

- Paper Presented on “Global Warming and its effects on Atmosphere” at SIT COEP, Maharashtra.

- 1st in Hidden Talent Competition in National Level Event at AISSMS IOIT Pune.

- 3rd in AVIATOR (Model-Airplane Making) Competition (Modern COE Pune.)

- Organizing committee member for at National Event –Engineering Today (AISSMS COE,PUNE)

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