Engineer Manufacturing

Shailesh Jaiswal, MS

Plano, Tx, 669-***-**** ****************@*****.*** https://www.linkedin.com/in/shailesh-jaiswal-96a6251a/

Manufacturing &Industrial Engineering and Lean Manufacturing Professional

Experienced Manufacturing and Industrial Engineering Leader with over a decade of hands-on experience, leveraging data-driven insights to achieve remarkable results. Known for a strong work ethic, effective leadership, and a mastery of Lean manufacturing principles that optimize operations, process flows, enhance productivity, and deliver tangible outcomes. A relentless problem solver, adept at identifying operational inefficiencies instituting comprehensive reforms to reduce costs and streamline processes.

• Leading the launch of the new R2 automotive model, managing the full product lifecycle from concept through production under an aggressive one-year timeline.

• Successful implementation of Autonomous Mobile Robot manufacturing processes with contract manufacturing facilities; Responsible for transferring knowledge, setting up lines, Training, validation of quality specifications, and capability of the line and equipment to meet the demand.

• Proven track records of improving bottom-line metrics to improve labor efficiency, cost, quality, delivery, and morale using LSS principles. Saved millions of dollars for all employers in terms of labor efficiency, reduction of scrap, and reduction of BOM cost.

• Designing and implementing systems, processes, and procedures to facilitate the smooth functioning of overall business/production operations and enhance operational efficiency with Industrial engineering and Lean Principles with a proven track record.

• Worked as a catalyst with all levels of personnel from front-line workers, lead/manager to Director level with continuous improvement mindset.

Professional Experience

Rivian Automotive: 02/2024 – Present

100 Rivian Motorway, Normal, IL 61761

Sr. Manufacturing Engineer

Responsible for analyzing, defining, integrating, and implementing manufacturing processes for R1 and R2 vehicles for Manufacturing verification builds, Supplier Approval Task and Mass production.

Worked closely with design, DFMA, Material flow and equipment teams, supporting design validation builds and leading manufacturing validation builds, delivering a proven and optimized factory to build efficient vehicle considering cost, quality and delivery.

• Lead manufacturing process development for R2 electric vehicle platform, focusing on scalable, ergonomic, and cost-effective assembly processes.

• Designed and validated assembly operations using data-driven methodologies to achieve volume, quality, and cost targets.

• Implemented innovative ergonomic solutions—including lift assists, reaction torque arms, and balanced material flow—to improve operator efficiency and throughput.

• Conducted line balancing using cycle times, CLL, and ergonomic criteria to optimize resource utilization on MA2 and TB1 lines. Reduced total assembly head counts from 26 to 22 using analytical data driven methodology.

• Partnered with DFMA, Design Engineering, Equipment, and Material Flow to ensure manufacturability and seamless integration of new products and tooling.

• Led waste-reduction initiatives through process mapping, layout optimization, and PFMEA-driven improvements.

ZEBRA TECHNOLOGIES: 1/2020 –12/2023

2811 Orchard Pkwy, San Jose, CA 95134

Advance Manufacturing Engineer

Pioneering the design, implementation, and enhancement of manufacturing processes for Autonomous Mobile Robots (AMR), focusing on optimizing productivity, labor efficiency, throughput, quality, and lead time across both internal operations and with contract manufacturers both within and outside of the United States.

• Conceptualized and executed manufacturing processes for electrical/mechanical assembly and functional testing of robots. A complete overhaul resulted in a lead time reduction from 7 days to an impressive 2 days. The application of Lean manufacturing principles elevated labor efficiency from 60% to 85%.

• Responsible for the transfer of complex AMR manufacturing operations from the US to Mexico, managing five distinct AMR transitions. Tasks included layout reconfiguration, line setup, equipment and tooling selection, SOP creation, production control system adaptation, and comprehensive training.

• Led a team in the improvement of First Pass Yield (FPY) for the F-100 using DMAIC methodology and Lean Six Sigma (LSS) principles, elevating FPY from 34% to 65%.

• Acted as a catalyst for process and cultural transformations, resulting in a 20% reduction in robot assembly cycle time through waste elimination techniques, workstation optimization, material presentation improvements, and Kanban implementation.

• Collaborated with contract manufacturers to ensure their manufacturing processes aligned with Fetch Robotics' requirements for production, quality, and capacity, promptly addressing manufacturing fallouts through the application of Lean tools such as 5Ws, fishbone diagrams, line balancing, PDCA, and DMAIC methodology.

• Demonstrated expertise in streamlining and enhancing production processes, identifying bottleneck operations, process rearrangement to minimize bottlenecks, waste elimination, line balancing, and lead time reduction. This approach improved throughput while maintaining a strong focus on quality and reducing labor and space costs.

• Continuously monitored and improved production fallout, collaborating with cross-functional teams and contract manufacturers to rectify, enhance, and elevate product quality through process improvements.

• Established and maintained comprehensive documentation, including Standard Operating Procedures (SOPs) and inspection checklists for assembly and extensive testing of all Fetch Robotics products to support day-to-day production and outsourcing activities.

• Guided a team of engineers and technicians in Kaizen events and Lean manufacturing practices, resulting in enhanced labor efficiency, improved line installation capacity, superior product quality, and a well-organized 5S-compliant production floor.

JABIL CIRCUIT, INC. (San Jose, CA):8/2013 – 1/2020

30 Great Oaks Blvd, San Jose, CA 95119

Lead Manufacturing Engineer

Define and implement critical manufacturing processes including complex electronics assembly for new and sustaining customers. Used industrial engineering, Manufacturing engineering, and lean manufacturing principles to improve manufacturing processes for box build operations considering cost, quality, on-time delivery, and morale. Drove and implemented PLM processes for its engineering changes, EOL, and RMA with proper documentation.

● Implemented the startup of new/existing projects of consumer electronics electro-mechanical complex assembly and box-build activities considering DFM analysis, optimizing cost, capacity, with improved labor efficiency and quality. Established and ensured process control and maintained appropriate documentation.

● Drove team of Manufacturing engineers and technicians for continuous improvement activities keeping in mind cost, quality, capacity, and customer satisfaction.

● Worked on consumer electronic FATP processes for definition, tooling requirement, setting up manufacturing execution and control system, feasibility study with a focus on improved labor efficiency for 12 subassembly lines and main device line.

● Collaborated with a multi-functional team to figure out very complex CTO (Configure-to-order) processes and record targeted TAT (Turn Around Time) for up to three hours.

● Implemented changes to continuously improve quality, process yields, and efficiencies through DFM analysis, PFMEA, Poka-yoke, kaizen,5S, cycle time reduction, and accurate visual aids which led to $200k in hard savings and 120k in soft savings in a year.

MITSUBISHI AEROSPACE: 4/2013 – 8/2013

6390 Northwest Dr, Mississauga, ON L4V 1J7, Canada

Industrial Engineer

Standardized the assembly process of Global Express aircraft wings for Skeleton, Box and Wing Tip assembly. Developed and executed projects to capture Standard Hours data for Aircraft Wing assembly processes. Applied lean manufacturing principles and implemented 5S to reduce the assembly labor cost by 15%.

JABIL CIRCUIT, INC. (Memphis, TN):12/2006 – 4/2012

5238 Lamar Ave, Memphis, TN 38118

Lead Industrial Engineer

Led a team of 10 Engineers to design, implement, and improve manufacturing processes for Network Appliance data storage system. Ensured smooth transfer of acquired business and collaborated with customers for process design, layout of production lines, manpower allocation, robust quality processes, demand fulfillment, designing of material handling processes, and procurement of all the equipment. Planned and successfully executed all NPI activities with internal and external customers.

● Managed and executed the successful installation of six production lines for new products in four months using Lean Manufacturing principles. The project timelines were met with time management skills in high -pressure and limited resources environment.

● Improved metrics like OLE, FPY, and Process Velocity in a Made-to-Order manufacturing environment from 60% to 75% using waste management, poka yoke and process mapping techniques.

● Drove Continuous Improvement activities in the form of Kaizen blitzes and A3 (PDCA) training plant-wide; achieved a savings of $290K in the first quarter of 2009.

● Analyzed all product families in customization area for complete process sequence and critical process steps using Stopwatch Time Study, bottleneck operation, material flow, and part presentation; productivity improved by 25% which resulted in annual savings of $150K for the company.

● Improved pack-out throughput in Isilon work-cell by 25% by analyzing blocking and starving situations, reducing variability and bottleneck through re-layout of the entire conveyor line.

● Led, defined and then implemented 5S program in all functional areas to cultivate culture; ran 5S competition among all work-cells for Memphis 5S excellence trophy; improved employee involvement from 0.15 projects per person to 0.26 projects per person; implemented visual management system at all critical areas of the plant to facilitate faster and accurate communication and rapid response.

● Efficiently identified and corrected flaws in manufacturing processes with simulations models for all customization area and improved costing up to 30% first time in Plant History.

● Originally hired as an Industrial Engineer; promoted to Lean Supervisor in August 2009.

Education and Professional Development

M.S. Industrial Engineering, Wayne State University, Detroit, USA; Aug-2004 to June-2006

B.E. Industrial Engineering, Vadodara, Gujarat, India

Six Sigma Green Belt Certification from Wayne State University, Six Sigma Green Belt (LSS) Certification from Jabil and Zebra; Basic MOST Certification from Maynard, Pittsburgh, PA, USA; Technically proficient in Delmia/Catia, Enovia, AutoCAD, Minitab, Arena & FlexSim, and Microsoft Word, Excel, PowerPoint, Project, Visio, and Google Workspace

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