Industrial Engineer Member Team
Resume:
ALI R. ELMI
Lake forest, CA. *****
949-***-**** • *******@*****.***
MANUFACTURING / INDUSTRIAL ENGINEERING
Supply Chain Management
Dedicated, performance-driven engineering professional with extensive experience within manufacturing/Industrial engineering and supplier chain management, in aerospace environments.
• Supplier Performance; capability, Capacity, Risk Assessments • Verification/ Validation
• Continues Process Improvement; • Production Start up/Readiness and Validation • Lean Principal: Standard Work, 5S, Kaizen
PROFESSIONAL EXPERIENCE
LOCKHEED MARTIN, VTR, Irvine, California• February 2021 – Present
Technical Subcontract Manager – Contract
Field position supporting the supplier chain engaged in manufacturing Aircraft parts, Assemblies, systems components for the Lockheed Martin’s Aeronautics programs such F-16, F-22 and F-35.
Duties & Responsibilities:
Providing onsite support at various major systems, airframe and tooling suppliers located regionally.
As a TSM member of supply chain management (SCM) team minimize the disruption to the supply chain by providing “in the field” oversight of supplier execution.
Working with supplier personnel to prioritize component through manufacturing, validating the status of deliverable parts and providing detailed status to procurement, preparing plans to reduce / prevent shortages, identifying risks in the supply chain, and developing risk mitigation plans to minimize the potential impact to the customer.
The Boeing Defense, Space & Security (BDS), Mesa, Arizona • March 2020 – September 2020
position supports the Apache Final Assembly & Flight Test and the various Fabrication Centers of Excellence (Composites, Metallics, & Electrical).
Senior Industrial Engineer – Contract
utilize industrial engineering concepts / techniques to partner with cross functional teams from production operations, engineering, quality, supplier management, materials management, and program management to achieve organizational business goals and objectives.
Duties & Responsibilities:
Directs and leads development labor hour estimates for new or revised production and tooling work packages by utilizing labor standards, tool and production design drawing reviews, and Tool and Production Operations concurrence to support program business.
Leads the identification and implementation of improvements to processes by analyzing current processes and utilizing established improvement methodologies to maximize the efficiency of equipment and personnel and to support company improvement initiative.
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ALI R. ELMI • Page 2 • *******@*****.***
GENERAL ATOMICS, Rancho Bernardo, San Diego, CA. October 2017 – June 2018
General Atomics (GA), and its affiliated companies, is one of the world’s leading resources for high-technology systems development ranging from the nuclear fuel cycle to remotely piloted aircraft, airborne sensors, and advanced electric, electronic, wireless and laser technologies.
Senior Manufacturing Engineer – Contract
Duties & Responsibilities:
Advise management of the status of work in progress, material availability, and potential production problems to ensure that personnel equipment, material and services are provided as needed. Manage and coordinates production schedules.
Assist in spares data mining and cost Analysis utilizing SAP and Windchill
Develop engineering change request (ECR) and submittal for and final approval for corrective action.
Participate In CNC setup and program Migration effort.
THE BOEING COMPANY, Everett, Washington • July 2011 – January 2017
Commercial aircraft manufacturer.
Industrial Engineer: Supported the commercial aircraft supplier management performance organization providing Industrial Engineering expertise to supplier’s chain in the support of procurement agents assigned to various product commodity’s (Interiors, Payload & Systems, MPA and Structures), regions (Domestic and International), covering all Boeing commercial platforms (737, 747, 767,777 & 787).
Statement of Work (SOW): Production Readiness Assessment support, Supplier Recovery, Time Standard development, Lean engagement; opportunity Assessment (OA). Root Cause Analysis (RCCA) and Rate Readiness Assessment.
Performed Rate Readiness assessment relative to Manufacturing and Assembly, Capital Equipment, Rate Tooling, Staffing, Facilities, Lean (Flow Reduction), Work Movements, Supply Chain, Business Systems, Engineering, Product Development and Quality / Delivery.
Major Achievements:
Supported Procurement agents to manage supplier/subcontractor performance and relationship to ensure delivery, quality, financial stability and in-service performance. Mitigates risks and issues.
Served as subject matter expert at production capability, capacity and risk assessment review.
Worked with supplier’s cross functional organizations to assess industrial risk, coordinate with procurement agents toward development and execute mitigation plans to ensure quality, delivery, and producibility requirements are achieved.
Identified root cause that will inhibit transition from development to production – partner with program management for timely closure.
Actively worked with Supplier in event of Quality or delivery issues to effectively define, create and validate both Corrective and Preventative actions.
Performed Validation of Supplier corrective action responses in effort to improve supplier performance. Utilize Risk Analysis for preventative action and/or Poke-Yoke.
ALI R. ELMI • Page 3 • *******@*****.***
DUCOMMUN TECHNOLOGY, Carson, California • October 2010– February 2011
Airlines/Aviation Industry.
Industrial Engineer – Contract: Determined root cause analysis of process problems through a coordinated effort with assigned operators, manufacturing, engineering and quality. Developed detailed work instructions, router creation and router updates. Assisted in transition of methods, processes and equipment during facility move. .
THE BOEING COMPANY, Everett, Washington • February 2009 – June 2009
A commercial aircraft manufacturer.
Manufacturing Engineer – Contract: Supported the 747-8 fuselage manufacturing as a member of the intercontinental raw material manufacturing engineering group. Determined availability of all materials for aircraft fuselage assembly, using production data module (PDM) software, as well as computer aided processes planning (CAPP)
Major Achievements:
Advised supplier management of master part list procurement and fabrication requirements in advance of the build schedule commencement, resulting in accurately identifying 12K parts, facilitating timely delivery and achieving full compliance to schedule constraints.
Completed contractor’s training in 2 weeks, achieving manufacturing engineering certification.
RAYTHEON SPACE AND AIRBORNE SYSTEMS, El-Segundo, California • March 2008 – June 2008
Engineering and manufacturing facility for the Raytheon Corporation.
Advance Manufacturing Engineer – Contract: Participated in VIIRS Cryo and the APS Glory program manufacturing and planning instruction development, utilizing standard space program templates. Conducted Planning Independent Review (IR). Made presentations for the Assembly Instruction Review (AIRR) and the No Doubt Critical Review (NDCR). Attended daily production IPT meetings that furnished manufacturing engineering status input.
Major Achievements:
Expedited 100% accurate space hardware documentation prior to payload launches with the development of manufacturing and planning instructions for VIIRS Cryo and the APS Glory program.
Facilitated comprehensive traceability of completed products and preparation for NASA product audit by developing all documents for customer buy off, and partnering in the recording of product documentation.
Successfully passed all space hardware planning certification requirements.
Earned a certification of Space Hardware environmental / process control and planning documentation.
Development of manufacturing and planning instructions for VIIRS Cryo and the APS Glory program.
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ALI R. ELMI • Page 4 • *******@*****.***
DAY-RAY PRODUCT INC., South Pasadena, California • April 2007 – October 2007
Manufacturer of lighting systems for Boeing commercial aircraft.
Production/Manufacturing Engineering Manager: Acted as the main point-of-contact for all manufacturing, production, engineering and planning issues related to accomplishing business performance objectives for quality, delivery and cost.
Major Achievements:
Instituted process mapping to prioritize and establish operations’ critical path.
Met business performance goals related to quality, delivery and cost by addressing all manufacturing, production engineering and planning issues.
Collaborated with Engineering, Procurement and Quality to ensure the efficient transfer to manufacturing, and the timely roll out of new products.
Assessed and documented all manufacturing processes.
Evaluated planning and re-sequencing of manufacturing processes.
Created employee cross training programs.
DRIESSEN AIRCRAFT INTERIOR SYSTEM, Garden Grove, California • March 2004 – January 2007
Manufacturer of galley systems for Boeing and Airbus commercial aircraft.
Lead Manufacturing Engineer: Directed a Lean manufacturing team in the establishment of lean methodologies across the organization. Conducted root cause analysis and executed remedial actions. Engaged in material disposition for non-conformances. Served as the MRB representative from the manufacturing engineering department. Developed manufacturing documentation. Held red line for further Engineering Change Order (ECO) authorization over engineering drawings and disposition material.
Major Achievements:
Reduced process cycle time, travel time and reduced material storage, and the build process by 12 days by creating production moving line through Kaizen event leadership; Established TACKT time and perform line balancing, identified tooling requirements, implemented 5S, and scheduled production control using just in time (JIT) for kit release.
Instituted a sole documented company procedure that improved all departmental communications with the creation of an Engineering Change Control System (ECCS) through Value Stream Mapping (VSM) implementation. Transformed current internal processes by eradicating non-value added processes and waste.
Eliminated product work redundancy at customer locations with root cause analysis, and implementing effective remedial actions.
Saved $100K in material costs by participating in material disposition activities to decrease unnecessary scrap.
Worked directly with Design Engineering team toward new product development failure Mode and effect Analysis (FMEA). Performed failure analysis and tracked first pass yield during prototype and initial production build.
Developed Manufacturing Plan and standard work for New Product.
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ALI R. ELMI • Page 5 • *******@*****.***
REMEC SPACE AND DEFENSE, San Diego, California • August 2000 – July 2002
Product & Applications: Military Microelectronic & Microwave Assemblies - High frequency subsystems for voice, video and data traffic over wireless communications networks including tactical aircraft, satellites, missile systems and smart weapons
Senior Industrial Engineer: Led the justification process for major capital production expenditures. Created advanced manufacturing technology and managed its production deployment. Developed and assessed new methodologies and tools.
Major Achievements:
Reduced labor utilization by 15%, and improved production performance by 45% by conducting work measurement, gathering and examining production data, creating and implementing standards, and performing production assembly lines layout for maximum optimization of production area.
Increased production output and quality while improving the build schedule with the introduction of new robotic equipment.
Facilitated an annual $250K in return of investment (ROI) savings.
THE BOEING COMPANY, Long Beach, California • December 1988 – July 2000
A major aerospace and defense corporation.
Principal Industrial Engineer: Directed industrial engineering projects, and owned responsibility for costs and scheduling while supervising the activities of an 18-member team of industrial engineers. Established performance goals, and drove accountability for manufacturing operations. Coached and mentored staff toward achieving their career objectives. Developed program strategic plans for executive review. Oversaw production performance with automated labor performance monitoring systems. Participated in the establishment of integrated labor usage, including crew cycling, learning curve implementation, shift and crew size analysis, as well as tooling capacity. Assisted in program planning schedules and “what if” scenarios that included recovery to schedule plans. Initiated operational performance metrics and performed process control charting to better measure and manage business performance.
Major Achievements:
Reduced production span time with workflow and manufacturing methods and critical path analysis, resulting in sequence change recommendations.
Provided clarity to team members relating to priorities and current status by monitoring critical paths with 1st line supervisors during Job Delay Summary (JDS) meetings.
Facilitated continuous improvement and variability reduction by implementing Process Based Management (PBM).
Achieved full compliance with program rate requirements by coordinating program strategic planning for executive review, identifying initiatives and tooling requirements while conducting capacity review, rate tool and schedule impact analysis, as well as make or buy decisions and cost justification.
Reduced the cost of aircraft from $240M to $120M by participating in must cost projects, conducting cost trade studies, and implementing productivity and efficiency initiatives, as well as lean manufacturing principals.
Enabled Air Force long distance mission readiness by confirming the expediency of the entire fleet being outfitted with a fuel tank bladder by performing a cost study in support of a project Design to cost and feasibility study.
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ALI R. ELMI • Page 6 • *******@*****.***
GENERAL DYNAMICS, Pomona, California – 1985-1988
Senior Manufacturing Engineer
Product & Applications: Military Micro Electronic Hybrid & Microwave Assemblies - Production of tactical guided missile and gun system
Increased product output, reduced manpower and cycle time by 80% by selecting, programming and utilizing full automated manufacturing support equipment.
Reduced 100% in inspection time and zero product defect by building inspection criteria in to manufacturing processes.
Trained and certified 30 production personnel in soldering electronic assemblies per military weapon specs.
Performed problem solving and failure analysis
HUGHES AIRCRAFT, Los Angeles, California -1983-1985
Senior manufacturing / developmental Planner
Product & Applications: Military Radar System and sub system assemblies, airborne radar system for Air Force F-14, F-15 aircraft.
Collaborated with program and project management in support, development and transition of new product to production line.
Determined fabrication for special assembly tooling, leading to $203K return on investment within the first year.
Designed and implemented a universal holding fixture to production assembly lines which produced $400K savings in fabrication cost.
TELEDYNE MICRO ELECTRONICS, Los Angeles, California - 1982 to 1983
Production Engineer
Product & Applications: Hybrid Micro Electronics for Military, commercial and Medical applications.
Supported an automation area within production of hybrid Micro Electronics production utilizing full automated production equipment. Trained production operators assigned to fabricating Integrated circuits (e.g. wire bonding, die attach, screen printing, hermetic Sealing, environmental testing, etc.).
Performed problem solving and failure analysis relative to material, assembly and test
Reduced 100% in inspection time and zero product defect by building inspection criteria in to manufacturing processes.
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EDUCATION
Bachelor of Science in Manufacturing Engineering Technology
Weber State University, Ogden, Utah
PROFESSIONAL DEVELOPMENT
Leadership Training and Certification - Boeing
Statistical Process Control Certification - Zodiac
Quality ISO 9000, 9001, AS 9100 Training
MS Project, Excel and PowerPoint Certification – Boeing
Windchill and SAP training and Certification – General Atomics
Supplier’s performance evaluation reporting system (Scores) - Boeing
Military Weapon Spec / MIL Standard Certification – General Dynamics
Manufacturing Support Equipment Certification – General Dynamics
Lean Principals, AIW Leadership Training & Certification - Boeing
Space Hardware Environmental / Process Control and Planning Documentation
Training & Certification - Raytheon
Supplier Excellence Alliances; Project Planning, Scheduling and Tracking -Zodiac
Production Data Module (PDM) and Computer Aided Processes Planning (CAPP)
Training & Certification - Boeing
Production Part Approval Process (PPAP), Data driven Improvement Cycle (DMAIC)
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