Saurabh Gayakwad

Detroit, MI 313-***-**** ac8khs@r.postjobfree.com linkedin.com/in/saurabh-gayakwad Technical Skills & Tools:

• Software: Minitab, Advanced Excel, Arena Simulation, Visual Basics (VBA), MS Office, MS Excel

• Experience/ Knowledge: Statistical Analysis, MSA, Root Cause Analysis (RCA), DOE, Lean manufacturing, Six Sigma methodologies, 8D, BOM, DMAIC, SPC, Kanban, Kaizen, DFMEA, PFMEA, GD&T, (QFD)Quality function deployment

• CAE/CAD: Hypermesh, Solidworks, CATIA V5

Experience:

Wayne State University – Post Graduate Research Assistant Jun'18-present I am responsible to assist department in ongoing research related to prosthetics and bionics.

• Conduct literature reviews, collect and analyze data.

• Prepare materials for submission to granting agencies and foundations

• Provide ready access to all data and study for the faculty researcher.

• Summarize project results, prepare progress reports for the faculty researcher

• Prepare other articles, reports, and presentations Indo German Tool Room - Quality Engineering Intern Jun’15-Oct’15 I was responsible for monitoring, evaluating, analyzing and maintaining quality of fabrication overtime. Find problems and suggest corrective actions, promote lean manufacturing philosophies and to deliver consistent quality.

• Successfully managed process of converting sheet metal into pipes within assigned budget and timeline

• Conducted time study and capability study based on PFMEA and created control plans for future prevention

• Collected NC tags by using Gage R&R and pareto chart analysis study and reduced them by 30% per month

• Assisted manager in preparation of APQP and PPAP documentation following QMS for Tool Room.

• Established 5S, and safety audit sheet following OSHA procedures, hence insuring operator safety and satisfaction

• Solved parts misaligned weld problem by conducting RCA study and suggested corrective actions

• Solved problem linked with metrology of exhaust pipes by using guides to assure consistency

• Created work instructions for assembly to reduce chances of error by new employees Gajra Gear PVT LTD – Engineering Intern May’14-Aug’14 Differential Gear manufacturer, customer requirements were to use a cost-effective method for structural analysis to meet ARAI approval on safety standards.

• Incorporated PFMEA & PFD control plans to resolve quality issues for new products, following QPAPA & PPAP procedures and then disposing non-conforming materials.

• Executed Toyota Production system (Lean Philosophy) throughout the assembly area driving continuous improvement and Kaizen events.

• Developed and documented new product quality targets and standard operating sheets for the shop floor.

• Led the process capability (Cpk) and M.O.S.T study to reduce bottlenecks, hence assuring parts fixature tools & product’s quality.

• Identified risk trends using reliability data and statistical analysis, decreasing the manufacturing cost up to 4.2%.

• Validate drawings in the system using solid works for various customers complaints.

• Used SAP and Syteline ERP system to maintain BOM schedule for the daily work orders. Indo German Tool Room – Internship Trainee May’13-Sept’13

• Collaborated with Senior Manager on PDCA, later switched to DMAIC cycle, ended up controlling major RPN’s.

• Hands on experience in implementing and auditing ISO 9001:2015 Quality Management systems with OEE metrics.

• Programs mills and lathes by entering G code instructions, including zero and reference points; compensation, setting tool registers, and conditional switches; calculating requirements, including geometry, trigonometry; proving part programs.

Academic Projects:

Scrap Reduction Using DMAIC Methodology- Paumac Tubing LLC Jan’17-May’17

• Led team of 6 members having different cultural background, with focus on minimizing communication gaps

• Organized GEMBA WALK with team to have initial understanding to develop across the team and employees

• Implemented six sigma (DMAIC) tools to improve quality & scrap, saving 20,000.00 USD.

• Performed measurement system analysis using Gauge R&R study and RCA on factors leading to non-confirming units

• Devised statistical process control (SPC) for assurance on quality and POKAYOKE strategies for error proofing

• Achieved improvements and a sigma shift from 4.2 to 4.3. Improved Cycle Time using Lean Manufacturing Methodologies- Paumac Tubing LLC May’17- Aug’17

• Led project with continuous improvement philosophy for further improvement of process

• Created project charter, documented voice of operator and issues occurring at work stations using Excel

• Developed current and future state value stream maps to understand the scope of process improvement

• Performed RCA on impact factors derived from Pareto Chart analysis of cycle times of different processes

• Implemented 5S and Mistake Proofing, improved value-added processes and reduced non-value add steps

• Achieved high quality process with scrap reduction of 47% Optimizing Refinery Production and sales – Saudi ARMCO Sept’16-Dec’16

• Created mixed integer linear model with logical constraints based on company’s preferences using MS Excel

• Performed rigor calculations and conducted 6 different scenario analysis using Excel solver and QM solver

• Integrated decision tree analysis to cross validate and to choose between different solutions

• Suggested new portfolio which can minimize the cost associated with transportation resulted in prediction of net profit increment of 19%.

Increased Productivity by Finding Relationship between Variables- Lear Automotive Corporation Sept’16-Dec’16

• Brainstormed to find cheapest way to improve production rate by optimizing material selection process

• Conducted multiple linear regressions to find relationship between trim thickness, foam pad thickness and density

• Devised tool using Excel VBA to save time consumed during decision making on material selection process

• Estimated cost saving of $87100 will be achieved due to reduced re-calculation time and process complexity Education:

• Master of Science, Industrial Engineering Wayne State University, Detroit, MI GPA-3.63/4 Sept’16-May’18

• Bachelor of Science, Mechanical Engineering RGPV University, Indore, MP (India) GPA-3.50/4 Aug’11-Jun’15 Certifications

• Lean SixSigma Green Belt

• Catia V5

• Hypermesh

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