Continuous Improvement Engineer

DEEPAK CHOPADE

***** * ********** ***, *** ***, Westland, MI-48185 409-***-**** ***************@*****.***

https://www.linkedin.com/in/deepakchopade/

PROFILE OVERVIEW

Manufacturing Engineer with 7 years of shop floor experienced in projects ranging from Continuous Improvement in Process, Production, Cost, Quality, Safety, Ergonomics, Project Management & problem solving.

INDUSTRIAL TECHNICAL SKILLS

Time study & Motion study, Continuous Improvement (Kaizen), Lean Manufacturing and Six Sigma Principals e.g., waste reduction, One-Piece Flow, SMED, product quality improvement

Line balancing, 5S, Poka-Yoke, Kanban, Process Engineering

DMAIC, PDCA, PFMEA, VAVE, problem solving by Root cause analysis (Fishbone, 5 WHY, 8D), Corrective Action Report (CAR), Statiscal Process Control (SPC), Value Stream Mapping (VSM), JIT

APQP, PPAP, MSA, Gauge R&R Process Flow Chart (PFC), KPI charts, Control Plan & Control documents

Process Optimization, Developing WI’s, SOPs and Quality Gates, JIT

Welding - submerged arc, MIG, TIG welding, flash butt welding

Design: PTC Creo Parametric 3.0, Solid Works, AutoCAD, Ansys Workbench 14.0

Software: MS Office, MOST (Time Study), MRP- SAP (Production Planning), C, Minitab

PROFESSIONAL EXPERIENCE

Manufacturing Process Engineer, Axiscades Inc Apr 2018- Current

Job Responsibilities:

Support manufacturing operation, production groups, translate product requirement into execution process

Provide technical input to development the process improvement, reviews capital projects

Provide direction to all manufacturing personnel in continuous effort to improve productivity

Responsible for managing manufacturing process elements of new product introduction programs

Take initiative in Continuous improvement projects, maintain all process data, document the process

Work to improve uptime, reduce machine downtime, control consumables usage

Manufacturing Process Engineer, Eaton Steel Corporation Oct 2016 – Nov 2017

Achievements:

Cost saving project completed- $120,000/year saving by implementing new tool design and tool holder modification (Continuous Improvement)

Improvement in tool change process- brought tool change occurrence from two per shift to 1 per shift by awareness and educating operators, $74,000 per year saving

Resolved biggest customer complaint- business challenge through automation to eliminate human error

Automation on line completed which replaces robots by conveyor scale. It reduces Robots downtime by 12% and increased overall production.

Improve and modify Plant layout to ensure optimum material flow without stoppages

Optimized cutting parameters reliable to both machine and cutting tool, increases overall tool life, also reduces frequency of change of tool

Worked on coolant leakages which saves wasting coolant and it also helped to keep work area clean

Job Responsibilities:

Problem solving related to process through DMAIC and PDCA, resolve customer complaints by conducting Root cause analysis by using lean tools like 5Why, Fishbone, 8D

Continuous improvement in manufacturing methods to improve throughput, product quality, safety, cost and provide technical assistance to shop floor activities to resolve problems

Work on set up time to reduce by using JIT and ECRS

Perform material flow analysis and optimize plant layout for best feasible material flow

Conduct Keizen and Pokayoke events on all segments on floor and idea generation by brainstorming

Value Stream mapping of production line and workload distribution based on machine capacity

Improve work ergonomics and make it easier for operator, follow EHS and OSHA regulations

Develop and manage capital projects, process improvement projects

Develop, maintain production process flow, write Works Instructions & Standard Operating Procedures and follow Good Manufacturing Practices (GMP’s),

Prepare Standard Work Sheets and Job Instructions sheets for existing and new parts

Conduct Time Study, Motion Study, reduce lead time, and work on machine downtime, increase awareness on floor about continuous production without stoppages.

Calculate the production cost, time involve, existing production resources, human resources.

Train and supervise staff on new development process and technology

Conduct and audit 5S activity weekly on shop floor and production office

Conduct tool study to find best tool for operation and to record tool life data, to reduce total tool cost

Design Part Geometry, Assembly Design in Creo and drawing sheet generation in Autocad

Work with suppliers & vendors to ensure delivery deadlines and quality of product

Worked on shearing machine with manufacturer to improve cut quality, straightness and overall aesthetic look of job.

Senior Manufacturing Engineer, Wheels India Limited Feb 2014- Dec 2014

Achievements:

Assembly plant layout redesign (AutoCAD) to reduce waiting time for raw material, CT optimized, productivity increased by 40%

Lead a team of five engineers in a project on cycle time reduction which resulted in reduction of cycle time from 14.5 sec to 12.5 sec, which has improved productivity by 20% per shift.

Reduction in Setup Time (tool change over time) from an average of 120 min to average of 45min which has improved productivity by 7% per setup through ECRS and JIT technique

Reduction of Minor Losses, Measurement and Adjustment Losses from average 7% to 3%.

Lead a team of four engineers in a project on scrap reduction which resulted in reduction of scrap from average of 18000ppm to 3500ppm which is a saving of more than USD $60000 pa.

Rework reduction from 70000ppm to 8000ppm.

Job Responsibilities:

Evaluate current processes for safety, quality, and productivity improvements through the use of continuous improvement activities

Component assembly by TIG welding, MIG welding, Resistance Welding such as Flash butt welding

Update and maintain documents include FMEA, Control plan, Process Flow Chart, WI’s, SOP’s, KPI trends etc. as per ISO / TS 16949.

Facilitates smooth functioning of overall production line and increase operational efficiency using One-piece flow, SMED, Time and motion study analysis

Reduced costs incurred in scrap & tool breakage using Root cause analysis & Corrective Action Plan, inventory management, Conduct Keizen and Pokayoke events for accident prevention

Ensure product quality by implementing quality gates and Statiscal Process Control (SPC)

Coordinate New Product Development project, draw plant layout, process flow chart

Maintain goods, raw material & spare part stock in ERP/ SAP system to ensure no stoppages

Initialization and implementation of continuous improvement ideas

Production Supervisor, Wheels India Limited Feb 2013- Jan 2014

Job Responsibilities:

Accomplish results communicating job expectations, planning, maintain discipline on shop floor by enforcing systems, policies, and procedures

Evaluate current processes for safety, quality, and productivity improvements through the use of continuous improvement activities

Completes production plan by scheduling and assigning personnel; accomplishing work results; establishing priorities; reporting results of the processing flow on shift production summaries.

Maintain quality system by establishing and enforcing organization standards

Ensures operation of equipment by calling for repairs; evaluating new equipment and techniques\

Provides manufacturing information by compiling, initiating, sorting, and analyzing production performance records and data

Maintains safe and clean work environment by educating and directing personnel on the use of all control points, equipment, and resources

Maintains working relationship with the union by following the terms of the collective bargaining agreement

Resolves personnel problems by analyzing data; investigating issues; identifying solutions; recommending action

Graduate Engineering Trainee, Wheels India Limited Feb 2012- Jan 2013

Job Responsibilities:

Learn about manufacturing processes in different areas of production, tool room, paint shop, quality assurance, maintenance, plant engineering

Learn about documentation related to manufacturing processes such as PFMEA, Control Plan, WI, SOP, APQP, SPC

Assess manufacturing processes for improvements scope and generate ideas for innovation

Recognize problems on production line, find out the solution

Industrial Engineer Intern, Poona Divisional Productivity Council Jun 2010- Jan 2012

Achievements:

Successfully completed manpower reduction project in TATA Motors (Marketing) and increased manpower utilization by 14% and thus overall efficiency

Productivity improvement done in VIP Industries by 24% and in Indo Schottle by 18%

Job Responsibilities:

To use Optimal manpower, sources utilization for productivity improvement

Line balancing, cost estimation, time study by MOST

To designs arrangement of machines within plant facilities to ensure most efficient layout.

To negotiate with workers to set up production targets as per ILO standards and final agreement

EDUCATION

Masters in Mechanical Engineering Jan 2015-Aug 2016

Lamar University, Texas

Bachelors of Mechanical Engineering Aug 2006- May 2010

JDIET, India

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