Industrial Engineer

SANDEEP SAIRAM Phone: +1-786-***-****

***** ***** **** ****, ********** Hills, MI 48335 E-mail: *******.******@*****.***

Graduate Industrial Engineer with background in Operations, Quality and Supply Chain Management.

2+ years of experience in manufacturing environment working with assembly, logistics, quality and inventory control

1+ years of hands-on experience in design and fabrication.

Skills

Design: AutoCAD, Creo Parametric

Statistical Analysis: Minitab, Microsoft Excel, Tableau, PowerBi

Computer: Microsoft Office Suite, ERP systems (SAP, PTSI), Visio, Think-cell, DIBS, PRISMA

Quality - Practical Problem Solving (PPS), PRT, 5S, A3, PDCA, 5 whys, 8D, Root cause analysis, Statistical Process Control (SPC)

Engineering - APQP, PPAP, PFMEA, DVP&R, SWI

Process - Continuous Improvement (Kaizen), Lean Manufacturing, Key performance Indicators, Poka-Yoke, Value stream mapping (VSM), process maps

Industrial: Yamazumi, Day-in-Life of (DILO), Multi Moment Analysis (MMA), Methods Time Measurement (MTM), Tactical Implementation Plan (TIP), Ergonomic Studies

Academic Qualifications

Master of Science in Industrial and Systems Engineering (M.S.E) Sep ’17 - Apr ‘19

University of Michigan-Dearborn, Michigan, USA. GPA: 4.0

Bachelor of Engineering in Mechanical engineering (B.E) Sep ’13 - Apr ‘17

Anna University, Chennai, India. GPA: 7.82/10

Work Experience

Logistics Process Specialist – Aerotek, Detroit Diesel Corporation March ’19 - Present

Performed Data Analysis towards improvement in process control including the development and monitoring of Key Performance Indicators (KPI)

Investigated material issues and reduced stockblock materials while tracking open tickets and negatives

Steered safety initiatives in the team and aligned with the plant safety team on ergonomic projects

Worked alongside quality and assembly teams to track and resolve quality and downtime issues

Led biweekly KPI meetings and resolved identified problems using Practical Problem Solving (PPS) methodology

Reduced $200,000 in repacking overtime costs by tackling packaging issues while coordinating with logistics planning teams and suppliers

Launched improved/structured Layered Process Audits (LPA) and Practical Problem Solving programs to proactively capture and resolve issues

Created process maps, PFMEA and control plans to identify process risks and developed / maintained documentation for IATF audits

Improved work allocation / production line smoothing using line balancing techniques and updated Standard Work Instructions (SWI)

Developed robust training programs and coordinated the training matrix activities for employees

Worked with cross functional teams and implemented auto-replenishment of materials from third party logistics (3PL)

Determined safety stock of materials using Bill of Material (BOM), setup systematic warehouse locations and material routing in DIBS and Plant Floor Applications for various process improvement projects and improved material replenishment process

Managed / assisted in CAPEX and finance decisions of the team and processed Purchase Requests (PR) / Approval for Expense (AFE) for various projects.

Owned and managed $500,000 project to repair / replace damaged warehouse racks and dock locks throughout the plant while working with facilities, finance and safety teams

Improved equipment efficiency of Powered Industrial Vehicles by developing a plan for spare hilos

Partnered with finance and IT teams and created a centralized End of Shift Report.

Worked with external vendor to develop and implement e-shop floor management

Internal Logistics Intern - Detroit Diesel Corporation, Daimler Trucks North America Aug ’18 – Feb ‘19

Reported daily KPIs to drive safety, quality and cost and sent out reports for regular Shop Floor Management

Worked regularly with cross-functional groups and used Daimler tools (Envision, Proview, PRISMA, PTSI, DIBS) to track downtime and quality issues

Applied statistical analysis on data to measure performance of team at various levels and and arrive at top issues to focus on.

Coordinated problem solving activities with the line supervisors to find root-cause for issues found and implemented corrective actions to improve the processes.

Drafted plant layouts and changes using AutoCAD to assist in process/layout changes and assisted in conducting workshops to train employees

Assisted in line balancing activities by performing time studies and ergonomic studies to find workload on employees

Coordinated with maintenance / facilities department to install boards, change layouts, stripe floors and installing equipments with error proofing measures

Standardized layered warehouse audit process to improve inventory accuracy.

Worked on inventory projects to identify discrepancies and reduce block-stocks of various lines.

Coordinated with implementing IT enhancements to improve communication between the departments in shop floor.

Manufacturing Engineering Intern - Sri Vinayaga Engineering Works Jan ‘17 – Aug ‘17

Diagnosed, identified and classified the type of problems in engine heads and blocks.

Assisted in conducting tests, collected, analyzed and reported data in laboratory to determine the lifecycle of valves.

Tested the leakage of engine head valves and implemented quality control in valve seating and assembly operations.

Worked in problem solving teams and process improvement workshops and performed time-studies and process FMEA to improve the process

Maintained engineering, change management documents and coordinated with relevant people for process and part changes.

Performed work sampling, capacity/ utilization analysis, KPI tracking to improve processes and eliminate waste.

Supply-chain Intern - Bike Terraine June ‘15 – Nov ‘16

Reviewed supplier/customer release schedules and tracked raw material replenishment to ensure production coverage

Scheduled build and communicated daily production build requirements to satisfy customer demand

Determined safety stock based on demand and delivery lead time to minimize inventory costs

Managed/tracked shipments and expedited inbound materials by identifying problems and resolutions

Coordinated with logistics service providers to improve transportation and delivery.

Improved delivery routes in the plant and reduced material replenishment lead time

Enacted quality control procedures in problem solving workshops to resolve assembly problems and optimized the process.

Supported manager in continuous process improvement activities and tracked KPIs to monitor progress.

Engineering Trainee - Process Engineer, Ford India Private Limited Dec ‘16 – Dec ‘16

Trained in blanking, stamping, metal treatment, engine assembly, body assembly, painting, quality check, and logistics.

Engineering Trainee - Process Engineer, TI Cycles of India Dec ‘14 – Dec ‘14

Trained in TIG welding, MIG welding, metal treatment, painting, powder coating, assembly, modeling, product development, QC- testing, package material testing and logistics.

Engineering Course Projects

Keyless Door Entry: Automatic detection and door opening – New Product/Concept Development Sep ’18 – Dec ‘18

A weight/force sensor senses a person standing on it and alerts another sensor on the door lock which senses the key within a specific range and then automatically opens the door with a hydraulic door opener.

Benchmarked functional specifications, developed concepts, analyzed using QFD & Pugh analysis, selected the best concept and final product specifications, created the BOM, performed DFMEA, designed the product using AutoCAD and performed time analysis for the final product assembly.

Design of rail guided system: reduce crane handling and waiting time June ‘16 – Apr ‘17

Feasibility study and design of a rail track mechanism to carry heavy components from one station to another inside the factory to reduce the usage of cranes which leads to less electric consumption and less waiting time.

Performed engineering calculations, parts requirements, component dimensions using design procedures and cost estimation and designed the model using AutoCAD.

Multimode steering: low speed rear wheel steering to reduce turning radius Dec ‘15 – Apr ‘16

The rear wheels are turned in a direction opposite to that of the front wheels using a bevel gear assembly whose gear ratio is calculated such that the rear steering angle is exactly half of that of the front wheels reducing the turning radius by up to 25%.

Designed the model using AutoCAD and performed engineering calculations, parts requirements and cost calculations

Mechanical stability control: controlled rear wheel braking to reduce skidding and understeer Dec ‘15 – Apr ‘16

A braking assembly used for the rear inner wheel reduced the turning radius of the automobile helping in parking, turning, maintaining the stability of the car and preventing wobbling when the automobile is steered suddenly.

Designed the model using AutoCAD and performed engineering calculations, parts requirements and cost calculations

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