Dipan Shah

ad03v1@r.postjobfree.com • Chelmsford, MA *1824

www.linkedin.com/in/dipan-shah-106a0a13/ • 978-***-****

Senior Program Manager Profile

Highly accomplished and analytical professional with 15+ years of experience in leading all aspects of key project, program, and portfolio management, operations leadership, process engineering, and production planning.

Demonstrated excellence in planning and directing large-scale engineering projects/programs from start to finish, creating strategic plans/control structures, and ensuring successful delivery on time, within budget, and as per the specifications. Proven track record of evaluating and optimizing program processes, improving resources, and implementing cutting-edge technologies to drive innovation, efficiency, and quality. Adept at resolving operational issues, managing scope, schedule, budget, and quality of projects and defining measurable metrics to foster program success and accomplish set targets with significant impact on departmental results. Passionate and visionary leader with remarkable acumen in overseeing, training, and guiding high-performing engineering teams to achieve shared vision and goals. Skilled in steering and executing transformative initiatives and contributing significantly to organization's success.

Areas of Expertise

Project & Program Planning

Operations Planning & Strategy Alignment

Resource Allocation & Management

Stakeholder Engagement & Influencing

Customer Relationship Management

Innovation & Change Management

Budgeting & Cost Management

Risk Assessment & Mitigation

Performance Metrics & KPIs

Continuous Process Improvement

Data Analysis & Interpretation

Vendor & Supplier Management

Engineering Leadership

Product Development

Technology Integration

Team Training & Leadership

Quality Assurance & Control

Project Tracking & Reporting

Signature Accomplishments

Planned and executed large-scale program (diabetes application), including purchase of CapEx over $1M for high-end molding cell; Managed entire program activities including FAT, machine/equipment installation, Inventorying of assets, process development by applying SIM principles and DOE to advance the program from validation Phase (IQOQPQ) to full production status efficiently.

Designed and led successful execution of streamlined production programs, including Kanban, VMI, and blanket orders to optimize efficiency and on-time delivery for specific customers.

Served as head of project management and technical sales, expanding customer's account from $800K to $2.5M with a focus on service revenue growth and winning new projects within existing accounts.

Improved 80% of tools/processes and decreased scrap by implementing tooling enhancements, acquiring suitable equipment, and automating procedures for consistent cycles.

Reduced setup time by 25%-30% and streamlined mold and barrel setup assembly across machines via improvement project.

Validated ERP system against real production numbers and boosted targeted profit margins via periodic BOM report reviews.

Led multiple time sensitive and critical projects during COVID, from tool construction phase to production with successful completion within given time, including the rapid development of ventilator components, cutting project time from 16 to 8 weeks, aiding Medical OEM's reputation, and addressing vital ventilator shortages in hospitals.

Guided customer with design feedback, materials and/or latest technology to overcome roadblocks with product development phase or scaling up; Proposed effective mold modifications to enhance machine yield, productivity, and reduce cost.

Identified and addressed machine alarms in injection molding, troubleshot issues, and built solutions to prevent downtime.

Career Experience

G&F Precision Molding, Danvers, MA Oct 2012 to Aug 2023

Site Engineering Manager

Delivered strategic leadership and encouraged a team of over five engineers and interns to achieve set goals. Drove technological growth and customer-centric approach for the company. By maximizing usage of resources. Ensured clear understanding of project scopes and successful achievement of targets within established timelines by collaborating with cross-functional teams. Identified and selected local vendors, such as toolmakers and automation houses to meet specific needs of projects. Engaged in extensive Design for Manufacturing (DFM) activities with customers and tooling vendors to develop functional, cost-effective, and high-quality mold designs. Troubleshot electrical and communication issues between molding machines, robots, and complex tools with core pull options.

Managed cash flow for entire engineering department projects, ensuring positive balance through meticulous ERP analysis and effective accounts receivable and payable management.

Integral part and contribution to G&F's growth strategy, growing company from 20 to 60 employees, with revenue surging over threefold from $2M to $7M as well as optimizing machine automation from 100% manual to 80-90% automatic operations.

Obtained competitive mold/machine proposals from suppliers, and generated proposals for customer’s projects with an annual revenue that ranged from $5000 - $ 10M and with a targeted profit margin.

Served as head of project management and technical sales, expanding customer's account from $800K to $2.5M with a focus on service revenue growth and winning new projects within existing accounts.

Headed R&D projects and facilitated rapid prototyping for customer account, including challenging applications, such as over molding with silicone on temperature-sensitive inserts and integrating technologies.

Conceptualized projects (septum assembly machine), reviewed the operations, and obtained quotes to assess Return on Investment (ROI) with automation houses, which eliminated five operation steps, automated remaining six steps completely, and gained 30%-35% profit on that project which passed 20% of it to customer for their ROI.

Developed and executed validation protocols tailored to fulfill specific customer requirements using stage gating method.

Experienced with risk management activities such as risk planning, PFMEA’s and developing control plans etc; Executed risk reduction/mitigation by conceptualizing cell layouts incorporating elements such as automation, Vision systems for part inspection, cavity segregation, and custom containers.

Voluntarily oversaw all aspects of construction project (facility/clean room expansion) as primary point of contact for construction firm with a focus on delivering project on schedule and within allocated budget.

Collaborated with production group to analyze components with highest scrap rates; implemented manufacturing process improvements or tooling modifications to reduce scrap and increase yield for five projects.

Leveraged strong experience in ISO 13485 compliance and class 7 clean room molding, driving continuous improvement through CAPA, and demonstrating proficiency in industry-specific quality and manufacturing protocols.

G&F Medical, Danvers, MA Sept 2010 to Oct 2012

Operations Manager

Oversaw external equipment and service vendors for new contracts and purchases, ensuring seamless integration and timely delivery. Managed inventory of raw materials, inserts, and finished goods using ERP system to optimize stock levels and reducing wastage. Conducted comprehensive training and development sessions for production crew to enhance processing knowledge and troubleshooting skills in LSR molding processes. Facilitated clear communication channels by delivering regular production updates through daily production meetings. Attended management review meetings, contributing to setting of yearly goals for operations and with other departments.

Attained key performance metrics, such as OTD of 98% or above, machine utilization, and scrap percentage under 8%.

Organized and delivered robust maintenance program for molding machines, metering equipment, and complex cold runner molds using ERP system for optimal performance and longevity.

Developed and launched effective Job book, detailing specific work instructions aligned with customer requirements to foster accurate and standardized manufacturing processes.

Prepared and controlled operations department budget with a focus on ensuring high availability of skilled labor, machinery, and equipment vital and supporting production and engineering growth.

Additional Experience

Process Engineer at G&F Medical, Danvers, MA

Engineering Intern at Jenline Industries (a division of Helix Medical), Gloucester, MA

Engineering Intern at Granite State Plastics, Inc., Londonderry, NH

Education

Master of Science in Plastic Engineering University of Massachusetts, Lowell, MA

Bachelor of Science in Plastic Engineering University of Massachusetts, Lowell, MA

Technical Proficiencies

SolidWorks, Mini Tab, Microsoft Office Suite (Word, Excel, PowerPoint), Microsoft Project, ERP System (IQMS)

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