Continuous Improvement Six Sigma

Mangesh Chaudhari

Email: *********@*****.*** Phone: 862-***-****

Lean Six Sigma Continuous Improvement Operations Leadership

Continuous improvement specialist with 13 years of Lean, Six Sigma, performance optimization experience and supervisory experience. Lean Manufacturing and Six Sigma practitioner, MS in Industrial Engineering and BS in Mechanical engineering.

• Lean Manufacturing Six Sigma

• Value Stream Mapping Lean flow methodology Zero defects

• 5S Visual Factory Visual management Waste elimination Gemba Walks Scrap Reduction Risk analysis Jidoka Cost reduction P&L

• IWS CT OEE OA TEO SQDCP

• Hoshin Kanri Strategic Planning

• Problem Solving RCA A3 6M 8D FMEA Heijunka

• DMAIC PDCA PDSA

• Poka-Yoke Error-Proofing

• SMED Setup time Reduction

• Kaizen Facilitation Pull Kanban

• Standard Work GMP CT JIT

• Process Optimization 3P Kaikaku

• Change Management Hansei

• Minitab MS office(Excel,Powerpoint,Visio), Smartsheet

• Supply Chain Optimization

• TPM TQM NCR TQC CAPA

• ISO 13485, 9001/2001 21CFR820 FDA OSHA

EXPERIENCE HISTORY

Radial Inc.

Sr. Continuous Improvement Manager Sept 2023- Present

Manage and drive operational productivity and efficiency(OE) of Radial network sites through the organizations Integrated Work Systems(IWS) with main focus areas such as zero defects, unplanned/planned down time reduction, waste elimination, scrap reduction, Equipment downtime reduction, best practices identification and effective implementation by coordinating and collaborating with various business groups such as engineering,manufacturing,quality,safety,maintenance.

Managing and deploying continuous improvement(CI) program and building CI culture at sites in US and Canada by holding Lean Six sigma training, mentoring lean trainees to identify and complete lean/CI projects on time, within budget and show sustaining results.

Leverage the lean trainees and site leadership to build CI roadmap for the site with ideas and initiatives in the areas of waste & scrap reduction, reduce quality errors, cost savings, cost avoidance,OEE,OA,CT reduction, reducing risk that directly impacts organizational KPIs and OKRs. Present the achievements to the executive leaders at company and client level. Build SME’s to drive improvements in their own areas

Facilitate improvement activities through Kaizens,Problem solving(RCA),FMEA,ideation sessions,PDCA exercises, change management to implement improvement changes. With the effective use of TPM and lean flow methodologies, build SME’s in respective areas to drive improvement that shows total employee ownership(TEO).

Radial Inc. Oct 2021 – Sept 2023

Continuous Improvement Manager

Deployed continuous improvement(CI) program and building CI culture at 7 fulfillment sites with 11 clients which includes site level standard process documents,production & workforce planning,VM,SQDCP,Org. structures,onboarding & training,LSW,best practices,employee suggestions,visual aids.

Consistently engaged with site leaders and senior leadership group to understand opportunities for improvement and identify current process gaps and develop strategy for improvement projects with CI champions and site leaderships.

Facilitated Kaizens to eliminate process wastes, errors, defects. Reduced lead times by 13%.

Pharmavite, California, July 2017 – Aug 2021

Industrial Engineer

Managed,trained and mentored managers and site leadership overseeing different CI projects with main focuses as OEE,OA,Cycle time reduction, Line balancing, setup time reduction, pull product support, Kaizen implementations, Kanban implementation, metrial handling techniques and Just-In-Time(JIT) to eliminate process waste and improve productivity. Reduced cycle time by 14%, setup time by 16% and improved productivity by 17% resulting in $723K in 2 quarters.

As per the organization’s Hoshin Kanri(Policy Deployment) & strategic business priorities, managed 27 Kaizens to reduce current delayed lead times, missed on time deliveries, process constraints, downtimes and bottlenecks in reference to Takt, gross margin and ops goals resulting in reducing setup time by 53% and savings of $3.2MM.

Trained & certified 73 employees on Lean Systems white belt covering various lean tools and facilitated 32 Kaizens to implement various improvements resulting in $1.35MM savings in 2020. Trained 235 employees on problem solving and tracked 73 major problems with PDCA & RCA approach resulting in $735K cost savings.

Trace A Matic, Texas Jan 2015- Jun 2017

Process Optimization Lead

Managed cost reduction projects in coordination with the production and quality team to reduce process wastes, optimize labor standards by performing time studies, work sampling, KAIZEN. Improved the production by 12% in 3 months and optimized direct and indirect labor by 15%.

Developed a CI roadmap for the site including waste reduction, zero defects, productivity and efficiency as main focus areas. Managed 6 major CI projects with SME’s support to reduce defects by 13%.

Collaborated with site leadership on planning for operational efficiency targets, coach leaders on lean methodologies.

Zimmer Inc., Warsaw, IN, USA May 2013 – Dec 2014

Sr. Operational Excellence Lead

Complete mapping current process to understand current state manufacturing processes of all metal and plastics implants and instruments. Implemented improvements to reduce the process waste resulting in increased throughput by 3 %( vs. target of 0.8%) within 3 months

Performed current state floor layout analysis to understand the current machine and equipment arrangement and flow. Identified bottlenecks and gaps in flow and developed a new layout to optimally use floor space. Reduced the finish product lead time by 11% with cost reduction savings of $200K in 2.5 months

Motorola Mobility Inc., Fort Worth, Texas March 2011 – Apr 2013

Sr. Process Optimization Lead

Managed and supported daily repair operations issues for repair suppliers. Coordinated with the cross functional teams to perform PFMEA to identify customer quality failures, risks and resolve them by developing corrective and preventative actions. Achieved the target of providing solution within 48hrs. Developed benchmarking KPI’s and implemented across all repair suppliers globally.

Completed total analysis on current repair cost, identify bottle necks, equipment down time, wastes in the process. Implemented 5 improvement projects to eliminate wastes. Increased production capacity from monthly $84K to 126K, reduced repair cost by 23%, Reduced lead time from 48hrs to 36hrs (savings $49K monthly).

Alphatec Spine, Carlsbad, California March 2010 – Feb 2011

Continuous Improvement Engineer

Coordinated entire project of a metal and plastic spine implant and instrument system from the beginning of development till ready to ship. Facilitated 5 Kaizen events and eliminated process waste by 23%.

Managed and contributed in cost reduction, continuous improvement and problem solving activities to resolve daily quality related issues. Increased the production capacity from 200 to 458 parts per day resulting in monthly improved revenues from 12k$ to 35k$

Performed risk analysis to identify potential failures, implemented improvements resulting in reduced failures up to 43% and reduced cycle time resulting in 33% production improvement

2007- 2009 University Of Texas, Arlington M.S. in Industrial Engineering GPA: 3.33

1197- 2006 University Of Pune, India B.S. in Mechanical Engineering GPA: 3.5

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