MANGESH CHAUDHARI

**** *********** **, *******, ** 77070,TEL: 862-***-****/acuttv@r.postjobfree.com

PROFESSIONAL SUMMARY

Coordinating and managing various cost reduction, continuous improvement, and problem solving projects for high pace and high volume production and assembly line environment industries like Automotive, Medical Device, Consumer electronics, Food products. Hands on experience in supporting Assembly line for production capacity improvement, quality issues resolution, continuous improvement, problem solving and establishing TQM,QMS,CTQ.

Complete Quality control planning and development, implementing ECOs and ECRs, test protocols and inspection methods, develop and implement complete inspection, testing and evaluation procedures. Quality issues resolution for in house production and at customer site related to non-conformance, customer complaints related to product and reliability issues by coordinating with various teams through WebEx, GoToMeeting and teleconferencing to get the resolution. Create training documentation to ensure best manufacturing practice and to achieve the best quality level which exceeds customer satisfaction.

Process improvement to manage Continuous Improvement, facility layout planning, material handling waste reduction, scrap reduction, lead time reduction, mistake proofing with the effective use of Lean six sigma techniques like DMAIC,PDCA,KAIZEN, PFMEA, 5S, 8D,RCA, CARs PARs, POKE YOKE, JIDOKA, Time study, value stream process flow mapping, line balancing, product performance analysis, life cycle study, gauge R&R, CTQ business needs.

New product introduction, Launch, support and behavior implementation. Developing and supporting PPAP, APQP, IQ,OQ,PQ activities complying with customer product specifications and design standards, implement design changes. Sound understanding of FDA, ISO 14971, ISO9001/2001, TS16949, IEC 60601-1, and IEC 62366 standards. Expertise in MS Excel, MS project, MS Visio, MS PowerPoint, Minitab, Solid Works, Auto-CAD, Epicor, JD Edwards ERP

Drive quality control activities for sampling new molds, identify quality issues in the injection molding process like flash, short shot, sink, splay marks, warpage, voids, bubbles, jetting and weld lines and resolve the issues by implementing corrective actions, develop and implement preventative maintenance activities for metals and plastic molds.

Sept 2014- Present

Trace A Matic,Texas, Manufacturing Engineer

Managed cost reduction projects in coordination with the production and quality team to reduce process wastes and improve current process by performing time studies, implementing KAIZEN. Improved the production by 12% in 3 months and reduced cycle time by 15%.

Led rapid action group to address customer quality issues by implementing a CAR PAR tracker, containment activities to identify and validate issues immediately and take corrective actions. Focusing on reducing the lead time for corrective action for issue resolution and with effective use and implementation of RCA and PFMEA reduced the lead time from 2 weeks to 1 week after the problem identification.

Keep track of Non-Conforming material Reports and record the issues, root causes and resolution in QMS system as lessons learned and documented for referencing to the upcoming familiar issues.

Develop cost effective (visual) work instructions for various complex manufacturing operations at cost centers and also implement display monitors to ensure the proper understanding and following of the assembly procedures in compliance with specifications and requirements.

April 2014- July 2014

Mobilenet Services, USA,Manufacturing engineer

Coordinated with engineering team to understand, identify current process wastes by performing RCA, value stream process mapping. Developed, proposed and implemented corrective actions for eliminating the wastes. Eliminated the wastes like time, transportation by 20% and improved productivity by 12%.

Formed the FMEA team of SMEs to identify and analyze the potential failures in the process. Prioritized failures based on their severity, defined and implemented corrective actions and updated the CARs &PARs tracker system. Eliminated the failures and established improvement in the detection controls by 50%

May 2013- Dec 2013

Zimmer Inc., USA,Manufacturing Engineer

As a active PPAP expert developed PPAP procedures in alliance with customer quality team and took full responsibility for customer PPAP approvals for new products. Effectively performed and developed control plans, process FMEA's, flow diagrams, Gauge R&R, CPK study for better understanding the current assembly line and manufacturing process. Being an active member of MRB resolved issues with non-conforming parts and implemented Corrective actions by performing Root Cause Analysis and implementing mistake proofing POKA YOKE. Improved issue resolution and re occurrence by 13% and also improved PPAP approval procedure time by 11% by proper coordination with supplier QMS and on site quality and R&D teams.

Supported assembly line for driving and managing various cost reduction, continuous improvement and problem solving activities using Lean Six Sigma effectively. Act as liaison between design team, supplier, and customer for design change and established a robust design change procedure. Provide onsite support for functional trials, customer complaints

Led various cross functional teams to coordinate and resolve customer quality issues by implementing Root Cause analysis, 8D problem solving,DMAIC procedures. Developed and negotiated quality specifications with suppliers for new product as required and developed quality specification standard, SOS sheet for supplier parts. Maintained weekly customer quality issues report by collecting data, generating Paretos, pie charts and graphs and Conduct audits of suppliers and contract manufacturing firms in order to determine the effectiveness of quality systems, capability to provide compliant product to the supplier. Improved PPM level of supplier from 10000 to 4000 in 4 months.

Involved in development of company Quality Systems policies, procedures and initiatives for driving continuous improvement and cost reduction projects for all aspects of the Quality. Participated in the development of institutionalized quality systems in compliance with ISO9001 & TS16949 and verification of documentation with ISO and TS16949.

Supported injection molding operation for process improvement and resolving quality issues flash, short shot, sink, splay marks, warpage, voids, bubbles, jetting and weld lines by implementing corrective actions, implemented contingency plan to minimize risks in the process

Used floor space planning data to understand the current machine and equipment arrangement and flow. Developed a new organized machine/equipment flow to use the optimum floor space required to establish an efficient and least time consuming process flow. Documented and presented the changes to the value stream managers, implemented engineering changes in coordination with manufacturing supervisors and line leads. Reduced the finish product lead time by 11% with cost reduction savings of $200K in 2.5 months

Assist Quality and reliability teams in developing PPAP documents and approvals for new product which meets Quality standards and meet customer requirements. Also conduct internal process audits to ensure the product quality in compliance with the FDA, ISO 14971, ISO9001/2001, IEC 60601-1, IEC 62366 standards and upload the quality documents to QMS system.

March 2011- April 2013

Motorola Mobility, USA, Manufacturing Engineer

Managed and supported daily repair operations issues for MRSCs (FLEXTRONICS, JABIL, and FOXCONN). Coordinated with the cross functional teams to perform PFMEA to identify customer quality failures, risks and resolve them by developing containment, corrective and preventative actions and update them in CAR PAR system. Achieved the target of providing solution within 48hrs

Identified and resolved quality issues at injection molding operations of battery cover, set top box bodies, walkie talkie bodies like warpage, flash, short shot,, voids, jetting and implemented corrective actions to avoid the re occurrence of the issues.

Studied the repair process flow to identify bottle necks, wastes in the process which reduces throughput. Implemented line balancing, automation, fixtures to eliminate station idle time and improve ergonomics of operators and improve their efficiency. Increased production capacity from monthly $84K to 126K, Reduced lead time for repair commitment from 48hrs to 36hrs (savings $49K monthly).

Studied the new product assembly process layout of complex components and sub-components and developed work instructions for operational procedures which ensure the high quality, least time consumption and are cost effective manufacturing solution in compliance with the specifications and requirements.

Validated the high priority issue of touch screen failure and managed the project of “Gorilla glass recovery”, “Master Swap” and “RMA” for touch screen, PCB and cell phone parts recovery projects. Formed a team of SMEs to drive project activities from start till the implementation by holding net meetings, teleconferencing and video conference meetings if required. Saved $0.5Million (vs. target of $0.3Million) by Q4 2012 with Gorilla glass recovery, $1.2Million by Q3 2012 with Master Swap and $0.8Million (vs. target of 0.5Million) by Q2 2012 with RMA project

Sept 2010- Feb 2011

Alphatec Spine, USA, Manufacturing Engineer

Coordinated entire project of a metal and plastic spine implant and instrument system from the beginning of development till ready to ship. Worked as a team member and project coordinator to drive and review new product development, equipment installations, process qualifications and validations with the effective use lean six sigma. Eliminated process losses like time, transportation and material handling by 23%. Successfully launched a spine fixation implant system resulting in revenues of $500k in Q4 2010

Supported injection molding stations for process improvement and quality issues resolution. Worked closely with manufacturing supervisor to track and monitor the issues occurring at the molding station and root cause the issues. Implement corrective actions and mistake proofing to eliminate the issues in future. Reduced quality issues re occurrence by 15% and improved product quality by 7%

March 2010-Aug 2010

Outsource Manufacturing, USA, Manufacturing Engineer

Managed and contributed in cost reduction, continuous improvement and problem solving activities to resolve daily quality related issues. Performed process flow mapping, spaghetti analysis, pareto analysis to understand current process performance, process failures, quality issues and opportunities to improve; implemented corrective actions and improvement changes. Increased the production capacity from 200 to 458 parts per day resulting in monthly improved revenues from 12k$ to 35k$

Identified high priority potential failures during the product development, analyzed risks involved and effects of failures to system; suggested and implemented improvement changes to reduce process failures. Reduced failures up to 43% and reduced cycle time resulting in 33% production improvement

July 2006- Aug 2007

Anagha Enterprises, Pune, India, Quality Engineer

Supported customer PPAP activities and approvals, initial trial runs for product of customers like TATA Motors, Force Motors. Work with customer quality team to develop the road map for the PPAP activities as per customer requirements, identify availability of resources and plan in advance to keep smooth flow of activities. Coordinate with management constantly about the progress of the PPAP and APQP procedures and use management support to escalate the activities for targeted completion.

As an expert of QMS developed Quality control plans for the production line for monitoring the current process performance and implementing DOE evaluated various operating conditions and defined optimized process for best quality product. Identified various special cause and random variations in the process by performing Root Cause Analysis and FMEA and implemented corrective actions, POKA YOKE and contingency plans to resolve the issues and reduce risks. Reduced process risks by 12% and reduced quality issues by 14% in 5 months. Improved issue resolution and re occurrence by 15% and also reduced cycle time by 10% by implementing 5S,KAIZEN,Line Balancing

2007 – 2009

1997 – 2006

University of Texas Arlington, USA, M. Sc. Industrial Engineering GPA:3.33

University of Pune, India, B.E. Mechanical Engineering GPA:3.5

Training

Six Sigma green belt

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