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Engineer Quality

Royal Oak, MI
October 07, 2020

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Akshay Kapade, CSSGB

Troy, MI – *****806-***-**** • • Education:

• Texas Tech University (TTU), Lubbock, Texas Graduation Date - May 2018 Master of Science Industrial Engineering (GPA- 3.5/4.0)

• Marathwada Institute of Technology (MIT), Aurangabad, India Graduation Date - July 2016 Bachelor of Engineering Mechanical Engineering (GPA- 3.8/4.0)

• Certified Six Sigma Green Belt (CSSGB), IISE Oct 2017 - Oct 2020 Relevant Experience

General Motors, MI, USA Feb 2020 - Sept 2020

Launch Industrial Project Engineer

• Supported internal IE team, lead and conducted manufacturing line trials for new electric vehicle launch

• Performed time studies, Material flow analysis, Direct Labor, Indirect Labor, and Ergonomic Studies, Vehicle traffic analysis to identify Non-Value-Added activities

• Standardized and audited operations (SOS), to reduce downtime and improve work force and layout utilization

• Validated multiple facility layouts using Auto-CAD, STDS/APS, reduced the non-value-added work, suggested line balancing activities resulting in elimination of additional operators and 4% possible reduction in cycle time

• Updated and reviewed Control Plans, Production Part Approval Process (PPAP) document for NPI

• Collaborated with PFMEA team to identify and establish error-proofing standards and methods for each part

• Boosted the material launch and plant supply chain group by identifying material handling, delivery, tooling method, implementing lean sequence, and kitting cell using PFEP to support front suspension line operations

• Ensured part availability, line readiness, and pre-requisite data for manufacturing line Trial, completed post-trial reports, analysis, and results, evaluated the success of each trial (yield, downtime, cost, safety, etc.)

• Joined forces with several cross functional teams regularly to create process scroll for future launch vehicle program and evaluate ergonomical assessment with Virtual Assembly team for new launch station operations

• Utilized Teamcenter for grasping production part details, drafted SOP for powertrain assembly and chassis line

• Documented and reported changes made in layouts, also responsible for initiating, and monitoring multiple PPCR

• Communicating with various cross-functional teams about changes on jobs and update JES (Job element sheet) High Country Millwork, CO, USA Oct 2018 - Oct 2019 Project Coordinator

• Executed 9 full lifecycle store/space development and planning projects for Retail and Hospitality clients

• Applied PMI tools like MS Project, Gantt Charts to ensure accurate project tracking, analysis, and saved ~10% of operational cost

• Governed the cost associated with ECO, led effort to lower engineering rework cost, saved $65K till date

• Spearheaded value stream mapping using MS Visio to track problem report cycle time and reduced it by 53%

• Worked closely with the senior management to develop S&OP and generated Manufacturing Capacity analysis reports to assist the business development team for targeting suitable potential business opportunities

• Managed all aspects of projects from inception to completion including project scope and project life cycle development, tracking budget, potential risks identification, risk mitigation and invoicing upon completion

• Outlined SOW, utilized work-breakdown structure to ensure efficient resource allocation based on cost estimates

• Pioneered project postmortems, maintained PM Team documentation using MS SharePoint

• Used Trak-ware, Epicor ERP system to track project related costs, gross margins and forecast accurate revenue

• Participated in Workplace Organization (WO) projects and conducted OSHA, BBS audits and Layered process audits to support and improve plant KPI’s

• Reviewed manufacturing drawings critically using Auto CAD, Inventor and Bluebeam on a regular basis while working closely with the Design and Manufacturing Engineering Teams Reliable Asphalt Products, KY, USA Jul 2018 - Oct 2018 Project Manager

• Provided consulting services to the clients regarding the Asphalt plant equipment setup and layout design

• Conducted project meetings and prepared reports to communicate the status of the project

• Utilized ComputerEase ERP software to track job costing details, inventory related cost and work in progress

• Ensured quarterly sales objective of $2M by collaborating with management, sales and service department

• Worked closely with both the sales and service departments to achieve operational objectives

• Created bids, change orders, track RFQ’s and report to stakeholders to assist in vendor and contract management

• Employed MS Access (SQL), Excel to generate the database for managing inventory, sales and business leads Ashok Leyland Pvt. Ltd., India (Tier one Automotive OEM) Jan 2015 - May 2016 Industrial Engineer

• Worked with cross-functional teams through the 8D process to identify the root cause of failures

• Performed Direct Labor, Indirect Labor, and Ergonomic Studies

• Conducted Line balancing activities to reduce labor idle time

• Developed and modified production line layouts using Auto-CAD, for optimized material flow, and waste reduction

• Utilized MS Excel to develop dashboards, interactive charts and graphs using VBA, V-lookup table for presentation and reporting purpose

• Assisted in Time Study and bottleneck analysis project for each workstation to reduce cycle time

• Utilized MODAPTS for multiple studies to validate operator movement times

• Deducted WIP by 10% and lead time by 15% using ARENA simulation models

• Supported IE Managers in various WCM pillars related projects for cost deployment, focused improvement, Workplace Organization, substantiated documentation for internal TS 16949 audits and APQP actions Varsa Plastic Industries Pvt. Ltd., India Feb 2014 - Dec 2014 Process Quality Engineer

• Designed experiments and conducted ANOVA to detect the impacting variables on injection molding process

• Reduced cycle time by 18% by eliminating special causes through Statistical Process Control and Minitab

• Facilitated Valve gating to reduce the cycle time and the shear rate for molding large parts

• Performed root cause analysis of returned customer parts and used the findings to drive CAPA improvements

• Conducted MUDA and MURA analysis to find out any variation in jobs as well as any NVA and Semi-NVA

• Achieved 40% reduction in the lead time in Customer Replacement Part Orders by validating root causes, implementation of DMAIC, KANBAN system to manage inventory, and the elimination of NVA activities

• Reduced freight cost by 8% by KANBAN execution that avoided stock-outs and need for expedited shipments

• Developed and deployed a framework of continuous improvement utilizing lean principles, KAIZEN and 5S

• Examined PPM tracking, weekly KPI report and scrap budget using 5 whys, Pareto chart

• Provided training to 50+ employees regarding the new technology and industrial work practices Academic Projects:

Project management of new biomedical product development (TTU) Aug 2017 - Dec 2017

• Managed a team of 6 to develop multipurpose joint supporting brace using CAD and rapid prototyping

• Performed technical, economic, capacity feasibility and stakeholder analysis of the proposed product

• Synthesized PERT, precedence diagram and critical paths to identify vulnerabilities in the project

• Conducted economic evaluation by NPV, Payback period analysis and Internal rate of return analysis

• Established Quality Metrics, QMS, RMS and EMS framework with adherence to ISO 13485 and 14971

• Proposed a detailed Human resource training and staffing plan for the acting organization Facility Layout Design for Plastic Manufacturing firm (TTU) Aug 2016 - Dec 2016

• Saved 20% of the space for future expansion by designing facility layout using AutoCAD, Factory Design Suit

• Developed multiple alternative layouts using Systematic Layout Planning method

• Examined the layouts using Weight factor, Total Closeness rating for better process flow across the facility SAE BAJA ATV chassis designing and strength analysis June 2014 - Feb 2014

• Designed, manufactured, and tested All-Terrain Vehicle using Pro-E, ANSYS

• Conducted FEA to validate the chassis using boundary conditions and concept of FMEA Skills:

• Process Improvement, KAIZEN, JIT, Pro-E, Labor Management, Workflow Optimization, Root cause analysis, PPAP, APQP, Process Planning, Lean Manufacturing, DMAIC, DFSS, ISO 14971, TQM, Retail Store planning

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