KEYUR VEKARIA

LinkedIn ac9zj0@r.postjobfree.com

Levittown, PA 19056 Cell: 352-***-****

Meticulous Process Engineer, who undertakes complex assignments and delivers exceptional output in distinct manufacturing environment. Over 7 years of hands-on experience in Process Optimization, Automation, Quality Management, Product Development, Systems Development, and Inventory Management. Leads multi-site Safety and Lean Six Sigma initiatives. Drives continuous improvement throughout the organization to maximize process efficiency, eliminate defects, reduce lead time, and reduce cost to raise profitability.

Core Competencies includes:

Project Management Toyota Production System Statistical Analysis & Report Writing

Budgeting Outsourcing & Contract Management Training Internet of Things

Internal & External Auditing MRP/ERP Software Systems Risk Assessment

PROFESSIONAL EXPERIENCE

Process Engineer Jan 2017-Present

Hutchinson Industries Inc. Trenton, NJ, USA

Hutchinson Industries is the premier manufacturer of mobility components for Defense & Aerospace industry, with a full line of products including runflats for various levels of security, beadlocks, 2-pc aluminum tactical and commercial wheels, protected fuel tanks, tire shields, and turn-key assembly services.

Raised overall Health, Safety, and Environmental standards up by factor of 30% in 38 different work cells within 3 manufacturing facilities, 2 warehouses, and 2 maintenance shop.

Lead CI program of 4 facilities and achieved quarterly targets of reported employee suggestions and dangerous situations for 2017 & 2018 by executing necessary solution.

Value Streamed operations by swapping 4 major production work cells between 3 manufacturing facilities. This lowered company’s yearly non-value added cost by $260,000 and reduced order turn around time by 3 days.

Monitor and track daily KPI's and conduct cross-functional weekly meetings to address potential issues and plan to ensure quarterly targets are achieved.

Lead and manage CapEx and Automation projects from generating concept to full execution. Conduct weekly reviews with automation team, mechanical engineer, and maintenance manager to develop plan and document progress to achieve targeted deadline.

Maximized equipment utilization of extrusion, molding, paint line, assembly, and packaging processes. Increased overall efficiency by 18% while maintaining initial manpower.

Trained Engineering and Product Development team to utilize Design for Lean Manufacturing to Standardize parts between different assemblies, minimize tool changeover, and set quality at source to eliminate future in process overhead. Used DFMA to develop manufacturing equipment and assembly process for mass production.

Developed Track Assembly of M88 Recovery Vehicle (new product market). Saved $540,000 in production rework/rejection cost by mistake proofing processes.

Primary liaison between Engineering, Quality, and Production Department for new product development (APQP), enhance technical features of existing products, and tooling/fixture development for production & quality inspection process of new parts/assembly.

Identified variations in BOM and implemented material Pull System (Kanban Cards) at 3 facilities. Reduced excessive inventory cost by $680,000 and saved $240,000 in scrap generated due to improper storage and handling. Developed specialized material storage/handling system and implemented FIFO.

Implemented Barcoded Data Acquisition and Andon system at 5 sites. Eliminated all paperwork and increased reliability & efficiency in tracking/tracing product defect. This system made it very easy to find and analyze data, identify root cause, and implement corrective action.

Helped company get certified with ISO 9001:2015 by conducting Internal Audit, generating NCR’s, and followed up with all department leaders to close the findings.

Wrote SOP’s for all equipment and production processes of two facilities. Trained operators with production process’s work instructions and risk assessment documents.

Sr. Manufacturing Engineer Sep 2016 – Dec 1016

Polaris Industries Inc. Roseau, MN, USA

Polaris is global Powersports leader, manufacturing and selling some of the best selling Brand’s of ATV’s, Snowmobiles, Motorcycles, Commercial UTV’s, Ultra-Light Tactical Vehicles, and Slingshot 3-wheel roadster.

Performed Assembly and Human Simulation to update current production operations & floor layout in CAD.

Practiced VSM to analyze current state, identified alternatives, optimized production operations and designed future state proposal for the re-vamp planned in December.

Streamlined assembly processes, removed 8 wastes, and optimized material flow to maximize capabilities and reduce costs.

Raised productivity by integrating sub-assemblies of Engine and Suspension Rail over on to main line.

Entire layout modification was done to increase reach for AGC’s which completely replaced use of Forklifts and Tuggers for material delivery and logistics.

AGC’s were able to deliver material directly to each station which increased safety, ergonomics, reduced time and burden to manually transport raw material carts from aisleway.

Manufacturing Process Engineer Aug 2012 - Mar 2016

White Wagon Pvt. Ltd. Rajkot, GJ, India

White Wagon is one of the largest producers of Small to Mid-sized Tractors for Agricultural industry, with fast growing dealer network under the name of Vaibhav Tractors.

Increased production capacity up by 35% by replacing entire manual assembly, paint line, and testing of tractors with automated conveyors, pneumatic tools, robots, and roller test bed designed with built in Safety and Ergonomic features.

Improved manufacturing Takt Time and redesigned assembly processes by regularly performing 5S, cycle time & motion study, line balancing and removal of Muda.

Used DFMEA tool to troubleshoot product failures such as starter motor burnout, failure of clutch assembly, hydraulic pump malfunction, sheet metal corrosion, oil leakages, cracking of casting parts, and bearing failures. Saved 175 USD/Pc in warranty claims.

Reviewed BOM at individual components level to reduce material/tooling cost by 15%. Optimized casting and fabrication parts’ design to utilize standard size hardware, lowered machining time, and eliminated unnecessary manual operations.

Reduced inventory investment by 11% and delivery time from 1 month to 15 days by using Just In Time & Pull system.

Saved $37000 yearly costs by practicing PFMEA and implementing Mistake Proofing methodology in material shortage, inappropriate storing & handling methods, quality control & testing errors, and irregular maintenance of all equipment.

Developed & Implemented new customized ERP software and transferred entire business database on a cloud based server.

Manufacturing Engineer Mar 2012 – July 2012

The John Deere Harvester Works East Moline, IL, USA

John Deere is the brand name of Deere & Company, an American corporation that manufactures agricultural, construction, and forestry machinery, diesel engines, drivetrain (axles, transmissions, gearboxes) used in heavy equipment, and lawn care equipment.

Increased and maintained production output from 25 equipment/day to 28/day, by identifying and eliminating 7 Deadly Waste through Time and Motion Study.

Practiced Kanban which reduced excess WIP inventory & scrap generation by 7% while improving on time delivery.

Investigated Quality issues with the use of 5 Why’, identified Root Cause and processed ECN’s with Poka Yoke solutions to improve product performance and production efficiency.

Updated BOM and submitted Production & Quality reports on the SAP. Identified and eliminated mismatch between actual BOM and SOP in the SAP system.

CAD Technician Sept 2011 – Jan 2012

White Wagon Pvt. Ltd. Rajkot, GJ, India

Designed surface (2D) and solid models (3D) of Tractor chassis’s components in AutoCAD.

Used SolidWorks to create Simulations to conduct Stress and Strain analysis.

Applied motion analysis to incorporate forces, dampers, sprains, and frictions to observe motion of the assembly and its errors.

CERTIFICATION

Internal Auditor ISO 9001:2015 May 2017 - Lifetime

EMS Safety: AED, CPR, and FIRST AID Aug 2017 – Aug 2019

ITAR/EAR Export Compliance Mar 2018 – Lifetime

Commodity Classification and Jurisdiction Mar 2018 - Lifetime

EDUCATION/AFFILIAITON

BSME, Temple University, Philadelphia PA Aug 2007 – July 2011

Member of SME, USA Mar 2018 – Mar 2020

Profecient in MS-Office, Outlook, MS-Project, SAP, AS-400, and Epicor Software

Multi-Lingual: Fluent in English, Hindi, and Gujarati. Beginner in Spanish.

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