Manufacturing Process and Design

HIGHLIGHTS OF QUALIFICATIONS:

*+ years of engineering experience in high volume ISO certified manufacturing facilities.

Hands on experience: Lean, Six Sigma (Flextronics Green Belt), KAIZEN, VSM, APQP, PDCA.

Blount certified Project Manager (PM).

Experience in Control Plan & PFMEA verification and validation as well as Overall Equipment Effectiveness (OEE) report generation, manufacturing process control using various lean methods.

Working knowledge of robotic welding, chrome-plating, stamping, wire EDM, sheet metal work and machining process.

Well-versed in CEC, ASME, CSA Standards (Z432, Z434, Z142, Z462, etc.).

Develop ECN/ECO for new process or new product introduction (NPI).

Read and analyze engineering blue prints including GD&T and dimensional layout.

Software proficiency: AutoCAD, SolidWorks, Catia v5, SAP NetWeaver730, Minitab 14, Microsoft Office Suite.

WORK EXPERIENCE:

Manufacturing Process Engineer Nov. 14 – present

Blount Canada, Guelph, ON

Lead and organize daily assembly meeting by gathering and presenting production data to managers, supervisors and team lead as well as addressing critical machine issues and solving it on daily basis with maintenance and quality team members.

Track, collect and analyze KPI’s (MTBF, MTTR, OEE, fault count, etc.) for performance and maintenance parameters using manufacturing cockpit to maintain equipment over specified time periods to improve equipment reliability and yield.

Operation, verification and troubleshooting of cutter chrome plating process.

Budget planning for capital and expense projects and tracking the costs in SAP. I am currently using the maintenance, purchase orders & cost control modules in SAP.

Routinely updated and maintained plant and machine lay-out using AutoCAD.

Performed process potential qualification both at vendor’s location and at plant. Including reliability run, functional testing, equipment performance testing, etc.

Support production by troubleshooting and optimizing plant automation, production floor support with any quality issues, making sure everything is up to speed and running properly.

Troubleshooting PLC’s (AB, Beckhoff etc.) and perform robot (ABB) teaching.

Standardize and document processes (PPS, SOP, POS, etc.) by writing new procedures or updating existing procedures.

Completed risk and hazard analysis for chain inspection, ERHT and chain assembly processes.

Supported Total Productive Maintenance (TPM) program development for chain manufacturing process equipment.

Solid modelling for custom parts of the machines e.g. cutter depositor, drive link magazine, rivet pneumatic cylinders, etc. in SolidWorks and machine some of these in wire EDM machine.

Currently implementing the "Best Practices" of TPM process used in Brazil plant into the Guelph plant.

Key Projects and Accomplishments:

As a member of the NPI team I am currently working on a multimillion dollar SRED project in which I am responsible for the development of wear resistance alloy welding, shiny rivet and tie-strap process of the project which includes conducting experiments, presenting results to the management. I regularly participate in APQP meetings to provide an update on manufacturing process related deliverables.

Custom-built chain assembly machine commissioning. Performed capability studies, planning, estimation, scheduling, and change management until project closing, coordinating and attending meetings with principals and vendors. Updated the assembly floor layout in AutoCAD.

Installed a Central mist collector (Donaldson Torit) which improves the air quality in the production floor as well as reduces power costs and maintenance time.

Modified the machine design and introduced a safety guard according to CSA Z432 standard to address a safety hazard for the operators. Updated the process documentation to reflect the changes and trained the operator & maintenance personnel on the modified process steps.

Installed a Gorbel Jib crane in order to improve the ergonomics and eliminate health and safety risk to the operators. Also involved in the PHSR done by a third party.

Performed commissioning and gauge R&R studies for the new Keyence brightness tester, Keyence image dimension measuring device (IM 6000) and Newage hardness tester (NI 600).

Purchase and commissioning of one Rotary 600 furnace including loading and unloading systems replacing the current AFC furnace.

Cutter Grind rinse dry station with a new mixer/dryer and cutter collection system to increase processing efficiency, eliminate rework and improve ergonomics.

Process Engineer Mar. 12 – Oct. 14

Flextronics Global Services, Newmarket, ON

As a member of the NPI Team supported new product launches, product design review and modification, engineering changes implementation, documentation, etc

Assisted in the development of training material and trained production personnel during new product introduction (NPI).

Identified bottlenecks and capacity constraints in the production process and used lean manufacturing techniques e.g. sequencing, load levelling, etc to eliminate these issues as KAIZEN team lead.

Performed process failure mode and effect analysis (PFMEA). Also did process mapping for specific processes, value stream mapping (VSM) of the entire process E2E.

Participated in activities pertaining to cycle time and process improvements.

Routinely updated and maintained plant and machine lay-out using AutoCAD.

Implemented statistical process analysis on new and existing process in order to reduce scrap and improve process by applying lean six sigma methodology.

Implemented safety, productivity and yield improvements e.g. securing all the working cells with proper ESD protection.

Prepared the control plan based on automotive industry standard practices and translated it into solar industry best practices.

Troubleshooting machine related issues e.g. electromechanical, hydraulic and pneumatic failure along with maintenance team.

Supported the QC department as required with customer concerns and corrective actions for 8D responses.

Key Projects and Accomplishments:

Automatic HI Pot testing machine design using Catia v5 for the finished solar panel which increased production by 30% from 232 panels/shift to 305 panels/shift.

Installed an automatic drum loading device for silicon dispensing station. Used AutoCAD for machine layout modification and Catia v5 for 3D solid modelling & simulation. This project eliminated the health and safety risk/concern of the maintenance technicians who had been loading the drum manually before. Hard saving $25,000 per year.

Designed an innovative bus-bar bending fixture using Catia v5 which reduced the cycle time and manpower thus saving $45,000 per year.

Installed 3 automatic backsheet and EVA cutting machine ensuring all safety standards and PHSR requirements are met.

Performed value stream mapping (VSM) of the entire process (E2E) identifying the bottlenecks in the current production process and did 12 KAIZEN projects on the basis of the findings.

Quality Engineer Jan. 10 – Feb. 12

Sunpetra Solar Energy Inc., Mississauga, ON

Quality control inspection: receiving, in-process, final and dock audit for the finished solar module including error proofing of the processes and compliance of the control plan requirements.

Developed forms and work instructions for recording, evaluating and reporting quality data ensuring accurate data collection.

Conducted daily audits of the whole process (front end and back end) and prepared daily defect report (EL failure, lamination defect, broken solar cell record, etc)

Recommended improvements of facilities, equipment and procedures to improve safety, quality, and efficiency.

Developed training materials for the employees and conducted training on the fundamentals of the quality, inspection and testing procedure and documented the training.

Conducted various testing on the incoming raw materials e.g. “gel content” test for the EVA, peel tests for ribbon-cell contact strength, etc.

Performed thermal analysis, immersion test, etc. of solar modules as required.

Assisted supplier quality engineer (SQE) to improve the quality of incoming raw materials through effective partnership with the suppliers.

Communicated routinely with customers, logistics, production and suppliers to proactively improve the quality of the incoming raw materials e.g. EVA, junction box, busbar, tempered glass, etc.

Key Projects and Accomplishments:

Set-up the quality testing lab from scratch which includes vacuum extractor machine, fume extractor unit, bench-top low pressure oven, etc

EDUCATION:

Master of Eng. in Mechanical Engineering 2009

University of Windsor, Windsor, ON

Bachelor of Science in Mechanical Engineering 2007

Bangladesh University of Engineering & Technology (BUET), Bangladesh

REFERENCES:

Available upon request

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