Engineer Injection Molding

Shiva Shanmugam Balasubramanian

PH - 313-***-**** E-Mail- ************@*****.***, Columbia, MD

Education:

Wayne State University, Detroit, MI, USA.

September 2009 - August 2011

Master of Science in Industrial Engineering.

GPA - 3.72

Coursework: Applied Engineering Statistics, Deterministic Optimization,

Production systems,

Fundamentals of Six Sigma, Lean Operations Manufacturing, Computer

Simulation, Supply Chain

Management, Operations Research, Six Sigma Green Belt Certified Graduate.

Anna University, Chennai, Tamil Nadu, India.

August 2004 - April 2008

Bachelor of Science in Mechanical engineering.

GPA - 3.7

Coursework: Computer Integrated Manufacturing, Production Planning and

Control, Process Planning and Cost Estimation, Total Quality Management,

Total Productive Maintenance, Manufacturing Technology, Engineering

Economics and Cost Analysis, Engineering Measurements.

Work Experience:

Bowles Fluidics Corporation - Columbia, MD

October 2014 - Present

Senior Industrial Engineer - Operations Analyst

. Capacity analysis for more than 300 injection molding tools

running on 85 injection mold machines and Capacity for over 90

Assembly lines in Fresnillo MX.

. Labor, Machine and Tooling investment analysis during budget

year (FY Start)

. Accessing the customer portal of GM, Ford, Chrysler, Toyota,

Honda, Nissan, BMW for responding the capacity analysis

. Forecasting Vs Net Requirements Vs Scheduled production orders

check

. Inventory reduction goal to 10%

. Tooling investment based on cavitation vs Press operating costs.

. Weekly and Monthly operations reporting. (Key Performance

Indicators)

o Efficiency analysis

o Plant Utilization.

o Plant Productivity ($ spent vs $ produced)

o Scrap.

o Inventory Trends, Coefficient of variation of inventory

Bowles Fluidics Corporation - Columbia, MD

February 2013 - September 2014

Industrial Engineer

. Developed PFD, PFMEA, Assembly Equipment Specifications, for the

new assembly products and new injection molding products.

Performed time study

. Cell layout design for Manual Assembly cells (Considered human

Ergonomics & human error)

. Cell layout for Injection molding cells on how to handle the

parts based upon the surface finish, time taken to cool the

parts. Recommended conveyors, EOAT (End of arm tool for handling

the parts, which has Class A surfaces and other critical

geometrical features.

. AX (MRP) - Assembly routes, Injection Molding and packaging

setup.

. Product Launches - (PPAP Approvals PSO Sign Off with Customer)

o Chrysler - UF, LA, LD, JC, LX

o Ford V363, CD539N, P552, S550, U502

o BMW F-15 and F16

o Merck - Aptar Copper tone Sun Screen spray - Annual volume

of 45,000,000 fluidic insert.

o Continental (EU Market) - Mini Coopers and BMW X-1 7mm Ball

insert assembly.

o Continental - Audi A4 and Skoda 12mm Ball insert assembly.

Fanuc Robotics -Rochester Hills, MI.

April 2012-January 2013

Manufacturing Engineer

. Responsibilities

o Leading the internal Manufacturing Kick off meeting for the

PAINT robots.

o Shortage analysis (Excel Model) to run the production in a

smoother manner for the BSG (Body Structures Group) Big

Three Projects (Ford, GM, Chrysler), Honda, Nissan.

o Updating the robot equipment configurations and BOM

adjustment periodically based upon the customer requirement

and engineering changes.

o BSG shipped robots reporting along with cost to the upper

level management.

o Coordinated the raw material flow from warehouse to the

concerned work centers in a timely manner.

o Returned the excessive raw materials leftover to the stock

through proper inventory balancing.

o MRP- (BAAN), Production Scheduling, Product routing from

"4" different ware houses to the respective work cells.

. Program launches

o Ford Kansas City and Flat rock robots

o Chrysler TNAP (Toledo North Assembly Plant), Chrysler

Saltillo, Chrysler (SHAP) Sterling Heights Assembly Plant)

o George Koch Kubota - P250iB Paint Robots

o Flex and Gate Mexico P250iB robots.

o GM Arlington Line A and Line B (P500iB Robots and Door

Openers)

Norgren Automation Solutions - Saline, MI.

Manufacturing Engineer

September 2011-March 2012

. Referred the drawings (Blue Prints) and created the process plan

by analyzing the plant capacity in order to make a decision for

manufacturing or to purchase the part by analyzing the previous

year usage, demand, quantity, labor capacity and also lead time

for almost 400 spare parts.

. Schedule weekly manufacturing review meetings to maintain

schedules

. Served as a liaison with groups such as Mechanical Engineer

department, Test Engineers, Quality Department, customers and

vendors.

. Also worked on determining the safety stock for the most

frequent and inconsistent demandable parts.

. I was in charge for creating the In Process inspection sheets

for the quality department. Worked aggressively by prioritizing

the dispatch list to create the sheets before the part hits the

shop floor manufacturing.

Goodwill Industries of Greater Detroit, Detroit, MI.

Industrial Engineering Internship - Lean Manufacturing Engineer

May 2010 - November 2010

. Designed Fixtures for assembling the automotive components,

conducted a time study and analyzed the bottle neck process and

finally suggested the most economical way of assembling the

parts in a minimum time span by using the solutions obtained

from the optimized spread sheet models.

. Introduced a new concept "Single Fixture assembling all the

incoming parts for assembly". By introducing that concept the

annual production cost was reduced to $20,000.

. Reduction in waste/scrap by 10% (Hose scrap and improper

assembly scrap has been reduced)

Wayne State University, Detroit, MI.

Research Assistant

September 2009-September 2011

. Worked under a Professor (Dr.Murat) in the Laboratory of

Industrial and Systems Engineering Department for my research

work "A Reminder Call Optimization Tool for Health Care Systems"

- MS Thesis Work

. OR (Operations Research) modeling was created using Excel Macros

and VBA.

Under Graduate Library - Wayne State University, Detroit, MI.

Student Assistant - Circulation Desk.

January 2010- September 2011

S.M. Pressings Private Limited, Hosur, Tamil Nadu, India.

Quality control Engineer

May 2008-August 2009

. I was in charge for the manufacturing of Connecting rod.

. Solved the root cause of improper finishing of the connecting

rod and also analyzed the bottle neck process in the Milling

machine cell for facing the boss of connecting rod and designed

a fixture to reduce the set up time and to increase the quality

of finished connecting rods. Increased the production to 15%.

And reduced the scrap up to 5%.

Technical Skills:

ANSYS V.7.0, Unigraphics, Autodesk Inventor V.7.0, CFD (Computational Fluid

Dynamics), Minitab, Arena V13.0, MS Office Tools, MATLAB, Pro-E (V

4.0),SolidWorks, AutoCAD. MS Office and MS Project.

Language Skills

German (Entry Level) and Spanish (Entry Level)

Reference provided upon request

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