Engineer Manager

ALI RIZVI

*** *. ********** ****, 708-***-****

Bloomingdale, IL 60108 ***********@*****.***

SUMMARY

Implemented Lean principles and continuous improvement to streamline processes and optimized resources to achieve optimal OEE. Lean Six Sigma Certified Green Belt.

Responsible for daily activities of plant operations which included scheduling, materials planning, sourcing strategies, staffing and capacity planning to meet production and quality goals and to ensure on time delivery of products. Developed budgets and forecast.

Managed 4 direct and upto 100 indirect reports.

Optimized staffing in Distribution Center (DC) pick operations by implementing Monte Carlo simulation module for load leveling staffing by zones. Performed Slotting analysis.

Developed budgets in excess of $30MM for 6 American Airlines operations.

Extracted data from WMS/ERP system, developed productivity metrics, KPI to monitor performance.

Conducted time studies and established time standards to project staffing requirements and improved labor utilization.

Responsible for maintenance and upkeep of facility and all equipment.

Collaborated with Marketing and Product Development to launch new products and develop pricing.

Experience with SAP Business One, Batch Master, Pick, and other ERP/MRP systems.

As Project Manager commissioned a Personal Care manufacturing plant from inception to completion.

Prepared operational budget in excess of $30 MM for six American Airlines airport operations.

Prepared standard operating procedures (SOP) in collaboration with production staff.

Minimized downtime by building a cross functional team and by implementing SMED and TPM.

Used MS Access, Excel, Power BI, SQL, ASP, VBA, to develop applications and generated analysis, forecast, productivity reports and metrics.

Lean Six Sigma Certified Green Belt.

EXPERIENCE

Woodward– Niles, IL 02-2020 –

Manufacturing Engineer (Contract)

Interfaced with Design Engineering in Industrialization of new products.

Established labor requirements, standard times, tooling, process capabilities, process flow, cost estimates.

Kester – Itasca, IL 03-2019 – 11-2019

Manufacturing Engineer

Established capacity analysis, equipment and labor utilization. Monitored productivity of Alloying, Extrusion, Sizing, Milling and Press Departments, by collecting data in Access/Excel and presented data in Power BI. Used this data to identify bottlenecks and worked on streamlining processes.

Develop and documented procedures to improve processes resulting in on-time shipments.

Participated in PFMEA and PPAP process activities. Prepared samples and reports.

LEARNING RESOURCES– Vernon Hills, IL 12-2017 – 03-2019

Sr. Industrial Engineer

Optimized staffing in Distribution Center (DC) pick operations by implementing Monte Carlo simulation module for load leveling staffing by zones.

Developed KPI metrics to monitor pick performance, and developed reports by items to optimize inventories levels.

Improved layout for Assembly area resulting in improved process flow. Increased production capacity by 25%. Improved work flow and implemented 5S.

Developed Labor Management System for assemblies which projected staffing requirements, production rates, labor cost for assemblies and setup.

US Pigment – South Elgin, IL 10-2015 – 12-2017

Industrial Engineer

Responsibilities included commissioning a Powder Coating automatic continuous line

Gathered project requirements, prepare capital plan, layout, and sized equipment.

Solicited quotes and awarded contracts.

Supervised the progress of the project and resolve any issues.

Procured Pretreatment washer, Dryoff Oven, Powder Booth and Electrostatic Spraying Equipment, Cure Oven (Infrared) and overhead conveyors.

PEACOCK FOODS – Geneva, IL 08-2012 – 09-2015

Industrial Engineer

Peacock Foods is a major co-packer for ConAgra, Kraft, Kellogg, General Mills, Tyson/Hillshire among many others.

Established, maintained and improved all areas of Operations and the Quality System using Lean principles to ensure processes are controlled, regularly reviewed, analyzed and reported.

Conducted time studies and established Time Standards, Standard work, SOP and collaborated with production supervisors to implement training programs, to improve the efficiencies of the lines and to meet the production and quality goals. Contributed as HACCP team member in developing processes.

Optimized line staffing by implementing line balancing and one-piece flow.

In response to customer RFQ, contributed as a team member in preparing ROI, EBITDA and pricing by establishing direct labor cost, Bill of Materials (BOM) usage and total material cost per UOM for the Team.

Enhanced warehouse efficiency by locating high velocity FG items close to the shipping and high velocity component items close to the production areas using slotting analysis.

Helped Production and Maintenance staff and developed Value Stream Maps to identify non value-added activities to eliminate waste in processes and in creating future state maps by leading the Kaizen Events.

Reduced downtime by implementing TPM, SMED and proper training of employees.

Developed Capex database application which monitored the progress of capital projects and approval process. Developed ROI analysis to justify capex projects.

Performed 5S, Single Minute Exchange of Dies (SMED), Value Stream Mapping (VSM), DOE, Statistical Process Control (SPC), Process Capability Cp, Cpk, Six-Sigma, TPM, Regression analysis.

AVLON INDUSTRIES, INC – Melrose Park, IL 04-2003 – 07-2012

Project Manager->Plant Manager

Responsibilities included developing the project requirements of hair care manufacturing plant from inception to completion after consulting process requirements with R&D and volume requirements with Marketing.

Established sizing of equipment, cost estimation, procurement of equipment, installation and startup.

Established the equipment requirements for manufacturing and packaging.

Determined the resource requirements, training, forecasting, budgeting, and development of procedures.

Collaborated with Marketing and Product Development to launch new products and developed pricing.

Optimized inventory levels by establishing Safety stock.

Developed and implemented sourcing and risk management strategies for components

With QA developed procedures for First Article Inspection (FAI) and other supplier development activities.

Implemented successful contract negotiations for the quality of products, price and timely deliveries.

Prepared the capital plan, and procured in-line fillers, rotary fillers, boilers, chillers, versators, jacketed kettles, vertical and horizontal holding tanks, vacuum pumps, compressors, positive displacement pumps, labelers, ink jet printers, load cells, tube fillers among many other equipment.

Collaborated with the Production staff and prepared SOP and trained the staff on established procedures and standard work.

Reduced the costs of operations and improved the quality of products by monitoring P&L statement and implementing kaizen to meet or exceed 80% OEE targeted goal.

As a team member contributed in the implementation of ISO 9000 2001.

WALLACE COMPUTER SERVICES – Lisle, IL 1999 –2003

Process Engineer

Conducted data transformation and data analysis for the production data of 20 manufacturing plants on monthly basis to generate KPI reports showing and comparing the productivity data, score card reports.

Generated and posted the performance charts on the intranet site showing the key performance indicators.

Contributed in developing the data migration and integration system from 20 locations.

Used data driven approach to identifying the best operators and learning best practices from them.

Extensively used Access and Excel in generating productivity reports.

Established/revised time standards when processes warranted.

Provided ad-hoc data to the Six-Sigma teams by running SQL queries.

EDUCATIONAL RESOURCES – Elgin, IL 1996 – 1999

Systems Analyst, Systems Department

Using Agile Methodology, performed Gap Analysis by gathering Business Requirement Document (BRD).

Developed stories form the Backlog list and collaborated with teams in finding solutions.

Responsibilities included designing, collecting, and analyzing the data for various departments using Access, Excel and Visual Basic.

Transmitted the 846 Inventory, 867 Sales, 850 Purchase Order documents and received 810 Invoices from our partner Microsoft.

AMERICAN AIRLINES – Dallas, TX 1988 – 1994

Budget Analyst - Eastern Division

Responsibilities included visiting airport operations and presenting budget analysis to the Vice President, and Controller of the Eastern Division.

Developed and monitored annual operating budgets in excess of $30MM for six airport operations.

Developed cabin work standards and developed processes, standard work with Industrial Engineering (IE) department.

Projected staffing requirements for airport operations and reached agreements with the Operations Managers on the optimal staffing needs.

Prepared monthly budget variance analysis and rolling three months forecast.

Performed analysis to determine impact of flight schedule and volume assumptions on operations.

Monitored productivity and unit cost performance. Presented monthly forecast to senior management.

Completed projects such as: cost savings projections and comparison analyses.

Monitored the Baltimore Terminal renovation project as Project Manager.

Reviewed and analyzed the Capital Requests determined the return on investment.

COMPUTER SKILLS

PC Skills: Extensively used Access, EXCEL, Minitab, Microsoft Project, Power BI, SQL Server

ERP/MRP System: SAP Business One, Progress, Pick, Batch Master

Languages: BASIC, FORTRAN, Visual Basic, VBA, ASP, VB.NET, ASP.NET

Used IQ (Interactive Query) to query data from AS-400, used Client Access. Gentran

EDUCATION

BS, Industrial Engineering

Iowa State University

Lean Six Sigma Certified

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