Process Engineer

IMTIAZ RANGREZ

**** ****** ****** ***********, ******* L4T 2W3

Cell: 416-***-**** E-mail: ***********@******.***

+ http://ca.linkedin.com/in/irangrez

Quality Assurance Inspector

Probes, tightens and simplifies systems, eradicating barriers to achieve operational success

Talented and persistent manufacturing change agent uncovers and steers continuous improvement initiatives to achieve maximum impact with minimum expenditure. Proactive and fair mentor and coach, seeks and values opinions, ignites collaboration and harmony establishing a performance-driven and team-spirited environment. Honest and frank communicator interacts effectively with all stakeholders, internally, externally and at all levels.

Core business strengths include:

Mid-Level Leadership

Lean Manufacturing

Plant Operations

APQP / PPAP

Problem Resolution Process (PRP)

Work Instructions

Kaizen / Kanban / 5S

Just-In-Time (JIT) Environments

Program Management

Root Cause Analysis

Continuous Improvement / DOE

Quality Assurance

New Product Launch

SR&ED Tax Incentives

Research & Development

PROFESSIONAL EXPERIENCE

Polytainers Inc. – Toronto, Ontario April 2017- Jan.2020

PROCESS ENGINEER

Improved manufacturing efficiency by analyzing and planning workflow, space requirements, and equipment layout

Assured product and process quality by designing testing methods

Tested finished product and process capabilities; established standards; confirmed manufacturing processes

Was actively involved in analysing current methods and processes; seeking developing, implementing, and documenting new best practices including start-roll out-sustain Kai Nexus CI Software through out the company.

Acted as SQF internal auditor for the facility-Focus on customer corrective actions and complaints (containment, root cause and short term-long term corrective action and closure) and their response to customer’s quality/warranty. Work with a various team to solve customer problems

Magna Exteriors- PPD, Concord, Ontario Aug. 2014 – March 2017

PRODUCT & PROCESS DEVELOPMENT SUPPORT (CONTRACT)

Developed, configured & optimized industrial processes; Assessed processes, took measurements & interpreted data/design; Ran, tested and upgraded the system and processes; Developed best practices, routine and innovative solutions to improve production rates, output, & manage cost & time constraints; Processed documents & instructions.

Demonstrated full participation to develop new innovative of Compression molded Carbon Fiber Hoods for 2016 Cadillac ATS and Carbon Fiber Composite GOR- RIW for 2016 Mustang Shelby.

Royal Building Products, Woodbridge, Ontario October 2012 – Aug 2014

C.I./PROCESS DEVELOPMENT.

Implement and train plant personnel for CI tools such as 5S, Kaizen events and Value Stream Mapping

Optimize manufacturing processes by collecting data, understanding trends and relationships, conducting design of experiments and establishing standards

Relocate Royal Patio Door plant facility; organize entire project; prepare and execute complete layout of floor plan and equipment; set up manufacturing work process flow; implement warehouse racking; manage and restore plant facilities to production including safety management

Co-Ex-Tec (Division of Magna International), Concord, Ontario 2002 – 2012

Played a key contributory role aligning the manpower, method and machines to streamline processes and boost efficiencies for the automotive sealing and trim manufacturer operating 24/7 with 3 shifts.

Held the following 2 progressively responsible positions:

PRODUCT PROCESS SPECIALIST 2011 – 2012

Promoted by the Plant Manager to identify improvement opportunities, redefine process parameters and workflow to obtain maximum output with minimum expenditure, devising, deploying and documenting research and development initiatives applicable under Canada Revenue’s SR&ED tax incentive program.

Made a notable impact in the extrusion department, reducing die changeover downtime contributing to an excessive labour expenditure in weekly overtime.

Conducted a time and motion study on the 110 minute 4-person changeover cycle, pinpointing a gap in process preparation and inconsistency between operators.

Sought team input and agreement of root cause, updated work instructions, created a detailed process checklist and trained all personnel in new work standard.

Trimmed 30 minutes (27% reduction) from process, achieving a Best Practice 80-minute cycle time, affecting 30 weekly changeovers, reducing labour expense by banishing the need for Sunday overtime.

Targeted a 20% reduction in extrusion start-up scrap, reducing initial waste from 250 metres to 200 metres.

Analyzed the existing PDCA loop process (Plan/Do/Check/Act) and presented a business case to senior management recommending the purchase of a $7,000 fixture to enhance the process.

Installed part, created a 4-person Kaizen team, conducted 6 R&D trials, adjusted process parameters, work instructions and trained 12 staff, attaining repeatable results within 90 days, eliminating 50 metres of scrap = $400/start-up x 10 weekly changeovers, providing a rapid return on initial tooling investment.

Interacted with Process Engineers, Production Supervisors, Quality and other stakeholders completing ongoing material and tooling trials and Design of Experiments, working with defined customer specifications.

Participated in all customer new product launch meetings providing design and process knowledge to elevate client confidence in selecting Co-Ex-Tec as a preferred Tier 2 OEM automotive supplier.

Acted as the Extrusion Department Manager mentoring and coaching a 60-person supervisor and operator staff complement, aligning shift skill sets to maximize productivity in a Just-In-Time delivery environment.

PRODUCTION SUPERVISOR – Extrusion Department 2002 – 2010

Reputed as an effective trouble-shooter, frequently allocated to revitalize production output and employee engagement, acquiring a wealth of expertise in all facets of the 3-facility manufacturing entity, steering a peak of 55 direct reports with shift targets of <4% scrap and 95% OEE.

Worked with a Six Sigma expert to conduct a detailed defect analysis, uncovering root cause of an unacceptable scrap rate generated at the seal splicing operation.

Completed process trials, updated process and rework instructions, lowering scrap from 40 to <5 parts per shift and increasing rework by 20% in 3 months, generating a total savings of $129,000 per year.

Collaborated with a 20-person team and internal consultant, applying Six Sigma methodology to boost extrusion and notching productivity increasing output by 120 parts per hour.

Partnered with the Chemist and QA personnel to secure a customer raw material specification change coupled with process enhancements, raising line speed from 16 - 20 metres per minute.

Redesigned and improved shop floor layout, repositioning from offline to online notching by Packers.

Initiative realized $308,000 in annual savings and earned members recognition at Magna’s high profile annual Winning Team Gala.

Instilled guidance, discipline and engagement, aligning employee performance and team skill set to company policies and shift goals, deploying visual boards to communicate daily KPI’s, setting the footprint for a harmonious, results-driven environment.

Hamilton Kent, Toronto, Ontario 1984 – 2002

PLANT SUPERVISOR 1999 – 2002

Championed all extrusion, fabrication and moulding processes for the 35,000 sq.ft. facility operating 24/5 manufacturing 5,000 rubber gaskets daily for the piping industry overseeing an 80+ hourly and leadership staff complement, continually monitoring and setting objectives to meet defined performance metrics.

Restructured staffing saving $50,000/year in extrusion labour costs without impact to production or quality.

EDUCATION PROFESSIONAL DEVELOPMENT AFFILIATIONS

Magna International, Concord, Ontario

CERTIFICATE: Spill Response and Chemical Handling 2011

CERTIFICATE: Lean Manufacturing - 2009, CERTIFICATE: Process Resolution Process (PRP) - 2004

Ontario Management Development Program, Humber College 1995-98

Diploma in Production management and Communication

Ontario Association of Certified Engineering Technicians and Technologists (OACETT), Etobicoke, Ontario 1984-85

CERTIFICATE: Engineering Technician. -Structural engineering.

DIPLOMA: Civil Engineering, Government Polytechnic, Gujarat, India 1980

Strong proponent of continuous learning; selected courses include:

Statistical Process Control

Advanced Product Quality Planning

Active Leadership

Leadership Strategies

Rubber Technology- U of Akron-Ohio.

IAPA Safety Management Certification

Contact this candidate