Quality Manager Continuous Improvement

LALIT DEORE

*********@*****.*** +1-469-***-****

PROFESSIONAL SUMMARY

Meticulous lean professional with 7 years of diverse experience, specializing in optimizing manufacturing processes and enhancing operational efficiency. Known for consistently delivering superior performance under tight deadlines, I possess strong analytical and problem-solving skills, which have enabled me to successfully lead lean projects and implement cost- saving initiatives.

EDUCATION

Master of Science, Industrial Engineering Aug 2019 - May 2021 The University of Texas at Arlington GPA: 3.4

Bachelor of Engineering, Mechanical Engineering Sep 2012 - May 2016 Pune University First Class

EXPERIENCE

Regional Quality Manager, Caresoft Global Inc. Full-time, Alcom LLC · Contract (Hartford, WI) Jan 2024 – July 2024

• Managed quality to address issues and drive continuous improvement using A3 action plan reducing warranty and rework cost by more than $250k.

• Led the Quality Control program to reduce Defects Per Unit (DPU) and improve quality score to above 90%.

• Implemented ABC analysis, PFEP and Kanban system to optimize tugger route and streamlined material flow reducing downtime due to material shortage by 100%.

• Implemented Lean Manufacturing practices from ground zero to lean excellence including 5S, visual management, Tier boards, Kaizen boards, shadow boards, Andon system ensuring improved productivity, safety and quality.

• Conducted time and motion studies to identify and eliminate bottlenecks, implemented line balancing and lean manufacturing principles, resulting in a production revenue increase to $1.44 million in Q2. Industrial Engineer II, Caresoft Global Inc. Full-time, The Toro Company · Contract (El Paso, TX) Feb 2021 – Jan 2024 Continuous improvement:

• Conducted Kaizen workshops to identify and implement improvement opportunities (130 kaizens), Major improvements- Central dust collector system and Deduster system to remove impurities from raw materials- Total savings $1.4 million.

• Performed Process Failure Mode and Effects Analysis (PFMEA) to identify potential process failures and implement corrective actions, improving process reliability and reducing failure rates.

• Initiated SMED (single-minute exchange of die) projects for extrusion lines and molding machines to reduce set up time by almost 50%

• Led lean projects to improve Overall equipment effectiveness (OEE) in extrusion and molding processes.

• Implemented TPM for CMMS, developed 20+ work instructions/OPLs, analyzed MTTR/MTBF metrics, improving equipment reliability and cutting unplanned downtime by 24%.

• Conducted Job Safety Analysis (JSA) to identify and mitigate workplace hazards, enhancing overall work safety.

• Deployed improvements horizontally across three sister plants while managing offshore team resources overseas. Production and inventory control:

• Developed a supermarket pull system that reduced 3PL and inventory costs in millions of dollars.

• Developed a capacity analysis tool to aid decision-making and increase machine utilization from 30% to 85%.

• Optimized returnable container tracking (RTI tracking system), resulting in annual savings of around $150k.

• Automated scheduling processes with macros and excel tools, reducing downtime by 70%.

• Supported the development of web-based applications IIoT cloud computing and dashboards. Process Engineer, Ameet Electro Systems (India) Jul 2016 - Dec 2018

• Conducted training sessions of more than 100 people to demonstrate the engineering concepts using demo kits.

• Implemented value stream mapping (VSM) to identify Muda and reduce process cycle time by approximately 60%.

• Led the team of 20 workers to achieve the target in takt time fulfilling customer’s requirements.

• Customer relation management to resolve issues, on-time delivery, keeping up the customer goodwill. Industrial Engineering Intern, Teekay Metal Pvt. Ltd. (India) Sept 2015 - Feb 2016

• Designed and developed a C welding torch fixture for LPG cylinders, reducing setup time by 90%.

• Automated the LPG cylinder logo printing process, cutting labor costs by 50% and reducing standard time by 60%. SKILLS & CERTIFICATIONS

Lean Manufacturing Tools: 5S, Kaizen, Just-In-Time, VSM Six Sigma DMAIC, DFSS, root-cause analysis: Cause-effect

(fishbone) diagram, 5Why, poka-yoke, Kanban, VSM, TPM, TPS, FMEA, Job safety analysis, spaghetti diagram, Non- destructive testing (NDT Level II), control plan, control chart, SPC, CAPA, MODAPTS, MOST time study, 8D Software: Advanced MS Excel (Macros, data analytics, pivot tables, VLOOKUP), SAP ERP, SQL, Auto CAD Certifications: Certified Six Sigma Green Belt (CSSGB) by ASQ (American Society for Quality).

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