SHAILESH JAISWAL

Cell: 408-***-****

*** ********* *****

San Jose, CA, 95123

E-Mail: ac8lc4@r.postjobfree.com

Profile

Over 15 years’ experience in Process design for CTO/BTO box build and FATP processes

Extensive experience in Process Enhancement, Business Improvement, Feasibility Analysis, Resource Optimization, Production Management, Project Management & Requirement Gathering & Analysis

Successfully leading team of four to support manufacturing industrial engineering processes

Designing and implementing systems, processes and procedures to facilitate smooth functioning of overall business / production operations and enhance operational efficiency with Lean Principles

Configuration of multiple Manufacturing execution system for successful implementation of manufacturing processes to meet customer requirements.

Performing root cause analysis to resolve internal and external non-conformities and taking necessary corrective and preventive measures to reduce and eliminate defect rates / defects

Direct, guide and coach engineering and cross functional team to achieve excellence in all endeavors.

Solid background in Lean Manufacturing with excellent knowledge of process mapping, scrap reduction, 5S, plant layout, simulation modeling, root cause analysis, 1-piece flow and FMEA.

Excellent track record of driving continuous improvement projects for all functional areas with emphasis on Lean Manufacturing principles, Employee involvement and Training to improve bottom line metrics

Professional Experience

Aug 2013 to Present Jabil Circuit Inc., San Jose, CA, USA

Lead Manufacturing Engineer

Implemented the startup of new/existing projects of consumer electronics assembly and box-build activities considering optimizing cost, with improved efficiency and quality. Established and ensure process control and maintains appropriate documentation.

Worked on consumer electronic FATP processes for definition, tooling requirement, feasibility study and improved labor efficiency.

Worked with multi-functional team to figure out very complex CTO (Configure to order) processes and targeting TAT (Turn Around Time) upto 3 hours.

Defined and implemented critical manufacturing processes like glue dispensing, torque driver calibration and pneumatic pressing considering all its process parameters

Understand and roll out engineering change activities and supported any BOM change that required to support CTO process. Recommended lean and faster conversion process to the customer to reduce TAT from 4 hours to 30 mins. Redefined the complicated BOM structure to define most optimum assembly processes for its repeatably, efficiency and quality.

Implemented changes to continuously improve quality, process yields, and efficiencies through DFM analysis, PFMEA. Poka yoke, kaizen,5S, cycle time reduction. Liaised with customers to understand their needs and convert them into actionable activities, delegate to the engineers for implementation on the shopfloor.

Successfully Implemented new shop floor system (Phoenix/i-factory) in 2 months of time to improve process control, reduced waste and automate the process.

Drove individuals and the team to continuously improve in key operational metrics and the achievement of the organizational goals. Led three kaizen for improving process flow, single piece flow and reduced space.

Prepared and supported manufacturing quotes and new product quoting by reviewing customer requirement, creating assumptions related to establishing a production processes and using analytical method of line balance and resource utilization.

Performed Process Failure Mode Effects Analysis to find out real route cause and improve yield.

Developed manufacturing equipment and process to improve safety, efficiency quality and ergonomics.

April 2013 - Aug 2013 Mitsubishi Aerospace Canada (MHICA) - Mississauga, ON, Canada

Industrial Engineer

Standardized the assembly process of Global Express aircraft wings for Skeleton, Box and Wing Tip assembly.

Applied lean manufacturing principles and implemented 5S to reduce the assembly labor cost by 15%.

Developed and executed project to capture Standard Hours data for Aircraft Wing assembly processes.

Jabil Circuit Inc., Memphis, TN, USA

April 2011 – April 2012 Lead Industrial Engineer

August 2009 – April 2011 Lean Supervisor

December 2006 – May 2009 Industrial Engineer II

Led a team of 10 Engineers to design, implement and improve manufacturing processes for Network Appliance data storage system.

Managed and executed the successful installation of 6 production lines for new products in 4 months of time using Lean Manufacturing principles like line balancing and optimization, capacity planning, systematic plant layout, 1- Piece flow, 5S and Visual Management. The project timelines were met with time management skills in high -pressure and limited resources environment.

Coordinated new business launch activities of large teams and kept them focused and motivated in times of crises which resulted in the most successful product launch in plant history.

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.

Improved metrics like OLE, FPY and Process Velocity in a Made-to-Order manufacturing environment from 60% to 75% in a short period of 3 months.

Ensured smooth interface with Global Lean Managers to define and implement lean strategy for the plant.

Drove Continuous Improvement activities in the form of Kaizen blitzes and A3 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 Stop Watch Time Study, bottleneck operation, material flow and part presentation; productivity improved 25% which resulted in annual savings of $150K for the company.

HDD assembly operations in Riverbed work-cell was one of the most variable processes in node assembly; reduced labor cost by 15% and improved UPH by 35% for all node assembly.

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.

Designed assembly line for Hewlett-Packard printers using systematic layout planning, lean manufacturing, MOST technique, line balancing and capacity planning.

Identified and corrected flaws in manufacturing processes with Simulation modeling for all customization areas and improved costing up to 30% for the first time in plant history.

Effectively used Arena simulation software to analyze blocking & starving phenomena as well as complex manufacturing system for Hewlett-Packard printer lines improving throughput by 15%.

Developed quotes for new business and rework for customers, as well as successful implementation of new products accounting for equipment requirements, floor space and process design.

Planned and successfully executed all NPI activities with internal and external customers.

Successfully improved manpower utilization and reduced labor for an annual savings of $175K.

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; Appreciated for improving company business

Developed and maintained production standards, documentation and work instructions.

Education

Master of Science (Industrial Engineering) from Wayne State University, Detroit, MI, USA.

Bachelor of Engineering (Industrial Engineering) from M.S. University, Vadodara, Gujarat, India.

Certifications

Six Sigma Green Belt Certification from Wayne State University, Detroit, USA

Silver Certification in Lean Six Sigma from Jabil Circuit

Bronze Certification in Lean Six Sigma from Jabil Circuit

Basic MOST Certification from Maynard, Pittsburgh, PA, USA

Computer Skills

MS-Word, MS Excel, PowerPoint, MS Project, MS Visio, MS Access

AutoCAD, Minitab, SPC XL, DOE PRO XL (Statistical Analysis Software), Arena11.0(Simulation Software)

Contact this candidate