Engineer Manufacturing

Sandeep Bagul

361-***-**** ***************@*****.*** Waukegan, IL 60085

Manufacturing Engineer recognized as an expert in manufacturing, assembly tools, and problem solving spanning product validation, process, tooling, risk analyze and visual aids. Proficient in quantitative, analytical and decision-making skills; sound knowledge of product support, cost analysis, and ability to multi-task. Expertise in capital projects, 8D problem solving, machine automation and line design. Maintains a focus on improving profitability by utilizing world class manufacturing techniques.

Skills

Engineering Support AutoCAD Factory Layout CNC

Control Plan Fixture Tool design Material Optimization

Product Validation Six Sigma Black Belt Design Verification

FMEA SAP Time & Motion Study

Experience

Aug 2019 - June 2020 Poclain Hydraulics Inc, Sturtevant, WI

Manufacturer of Radial Hydraulic Motors, Agriculture ML MS and MG motors

Project Manufacturing Engineer

* Provided manufacturing engineering support for Radial Hydraulic motors & pump

* Manage Production needs through Safety, Quality, Cost and deliverable KPI

* Managed FMEA on motors and provided process validation and test result meeting customer needs

* Used SQL for database access to multi level bom and execution for subassembly triggering

* Designed and Implemented lean project on Satellite Line and ML assembly line through kaizen

* Reduced floor space 40% and improved throughput by 85% on assembly line

* Increased labor efficiency by 35% on the lines

* Ensure CAPA through QRQC and action on production process and design product

* Suggest proposals to design in conjunction with testing and hardware parameters on assembly line

* Analysis on line side kanban, route mapping

* Make fixture and tool requirements liaison to CNC and design specific to regulated motors

* 8D problem solving for product through processes and customer liaison feedback

* Analysis on block castings for Agricultural motor and test bench parameters for NPD motors

* Design release for vendor approval through change notice

* Manufacturing capabilities at production line according to design specific implementation

* Worked on Standard work instruction and PFMEA for the radial motors

* Support Project Management across multi project handling

* Earned standard hours updating for routings in ERP system

* Design of Tool fixture and request for quotation from local Vendor

* Budgeted Capex approved and project execution on $100,000 capital investment and claim on return of investment of 1.5 year

* Action on issues related to manufacturing process, product and design through quick response quality control program on Microsoft teams

* ISO documentation for finished projects

* Product validation plans and test on NPI motors to meet quality and technical requirements on customer platform

* Cpk analysis and Statistical process control on machine acceptable performance at optimal level

* Carried out Factory acceptance Testing and Site acceptance testing on Piston Machine

* Improved Poke yoke on Piston Machines with targeted takt time

Jan 2014 – Aug 2019 Bombardier Recreational Product US Inc, Sturtevant, WI

Manufacturer of Jet propulsion engine, Evinrude E-TEC motors

Manufacturing Engineer

* Provided manufacturing engineering support for 150-300 HP jet propulsion engines, inline & v6 60-175 hp engines, Evinrude 175-300 hp engines

* Installed tooling, fixture, set process work instruction sequence for assembly line

* Experience in Cleanliness and packaging for Jet propulsion engine kitting and pump solution

* Used Python for Capacity Modeling of variation of part number engine sku

* Troubleshoot and find root cause through DMAIC problem solving

* Process optimization with DOE and root cause analysis on design processes

* Carried functional ECM Test through can interface on Jet Propulsion Engine

* Worked on New production introduction, develop pilot plans and validate against prints

* Worked on defect product and rework on the quality reapproval

* Saving Scrap $/hr through scrap management program and reprocess engine components back to assembly line

* Coordinate with design and manufacturing team for meeting technical solution for design specific, quality and customer needs on evinrude motors

* Write Standard Work Instruction for pilot engine and mitigate pfmea from quality needs and work on control plans

* Risk Analysis and collaborate with cross functional team, develop plan and execute on quality side of product.

* Design flow maps and maintain process validation of evinrude motors

* Saved $500K annually by implementing 2 bin system approach with 2 hr milk run from supermarket to line flow rack reducing Line side 5 day inventory

* Reduced finished engine buffer cost $97K by implementing pull approach using Kanban

* Saved $201K/yr from Kaizen event

* Improved throughput by 3% on push bearing shaft line by installing a hydraulic press

* Achieved machining of 10 engines/hr across 3 shifts by performing capacity planning for 8 engine block variations

* Saved $134K/yr in overhead by justifying labor work content cycle time

* Conducted lean projects:

- Removed 7 deadly wastes using 5S

- Resized flow rack using one piece flow approach

- Increased throughput 85% and reduced floor space 30% through line balancing and cycle time reduction using time study

- Implemented Poka-Yoke vision system on reverse gate pump station and volt regulator

- Implemented vision electronic Kanban screen for mixed model engine buffer for FIFO pick

* Reduced CNC honing tool setup time from 45 to 25minutes using SMED

* Designed machining layout for CNC cell and processed using single piece flow

* Designed plan for recall motor and immediate worked on execution on repair loop and maintain quality conformance of the evinrude motors

* Installed and commissioned $1M capital tool acquisition that included gantry hoist, workstation, wifi guns, fixtures, hydraulic press machine, robots, and automated guided vehicle

Nov 2010 - Jan 2014 Axis Inc, Seguin, TX

Diesel engines manufacturer for Caterpillar

Manufacturing Engineer

* Provided Product, planning, process validation and capability and test support on Diesel Engine.

* Decision making on product quality and improved quality 15% using FMEA on c15 diesel engines

* Product Problem solving, Finding root cause through risk analysis and decision making on quality requirement check sheet for customer requirement

* ECR management to improve process, BOM, tooling, and work instructions

* Added tooling for diesel line and egress for reject engines to eliminate bottlenecks, and rebalanced work content by adding new high volume station to reduce Takt time

* Performed line balancing of ATA-APA workstations using virtual builds for NPI, Vismockup Catia mockup team center, Caterpillar tooling guide handbook, and followed up pilot validation engines

* Utilized various torque tools in processes, e.g., GCI Arms to lift engines, ETV angle nut runner tool, Atlas Copco wifi transducer tool angle gun and wifi transducer wrench tool, High torque multi-spindle tool, lifting devices and battery-operated guns

* Performed subassembly scheduling, process routing, engineering change requests, process change numbers, tooling, visual aids, ERP BOM, and Job Manager

* Utilized Plexus ERP planning application for ECNs and BOM

* Resolved unplanned subassembly build issue on fuel filter base, oil filter base, oil cooler and Nitro-oxide reduction system cooler

* Performed pFMEA and control plans, root cause analysis and customer improvement cards

* Performed process workflow and station layout for c9 engine NPI launch project

* Trouble shot line problems, operator tooling issues, and visual aide issues

* Developed different angle torques for Spindle DC driver and Atlas Copco wifi tools

* Created the error proofing charts for each function of the system on floor

Sep 2010 - Nov 2010 Avanzar Interior Technologies San Antonio, TX

Johnson Controls subsidiary - automotive interiors for Toyota, Texas

Continuous Improvement Engineer Intern

* Improved throughput 80% and reduced non-productive activity 20% through Value Stream Mapping

* Decreased Takt time 4 minutes by conducting Time and Motion Study of routes feeding the welding line

* Saved 1.5 hrs non-value added forklift routes by carrying out DMAIC on warehouse SKU optimization

* Gained fabrication, welding, assembly and finishing experience

* Primarily involved in DMAIC, routings, work and time study

Education

MS in Industrial Engineering Texas A & M University, Kingsville, TX

Dec 2009 GPA 3.41/4.0

Bachelor of Mechanical Engineering University of Mumbai, Mumbai, India

Nov 2003 GPA 3.50/4.0

Research Projects

Computer Simulation on Toyota Production System

* Simulation on daily production analysis of 30 manufactured vehicles by using arena software

Study on Co-ordinate Measuring Machines and their Application

* Collected data, analyzed application of laser scanners depending on scanning points per second

Presentations

Lean manufacturing in pen Industry Texas A & M University

Literature review-Enterprise integration, CIM and Future Trends Texas A & M University

Technical Skills

Arena 7.01, Promodel 2018, AutoCAD, Vismockup Catiateam center, SAP, JDE, Creo, PTC Wind-chill, Microsoft Application, ERP, Solid edge, Solid works, SQL, python, MES, MOST, Jira

Memberships

Institute of Industrial Engineers, Lean.org

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