Mechanical Engineering Six Sigma

Irfan Ahmad

*** ******* ***** **********, ** ****5 607-***-**** *********@*****.***

Public

Education

• MS, Mechanical Engineering: University of Oklahoma

• MS, Nuclear Physics: Quaid-e-Azam University

• BS, Mechanical Engineering: University of Engineering and Technology Professional Skills

Quality

• Certified Six Sigma Blackbelt, Lean SME

• CQE, ASQ

• QMS development and Implementation

• APQP, PPAP, CAPA, 8D, SPC, FMEA, Pareto Charts, Fishbone Diagrams, GR&R, Six Sigma, Shainin

• Scrap Reduction & Throughput Increase

• Systems Design & Automation

• ISO 13845/AS 9100/IATF 16949, Quality & Capacity Audits

• Geometric Dimensioning and Tolerancing (GD&T) – ANSI 14.5 Lean Manufacturing

• Lean digital transformation of conventional manufacturing lines

• Continuous Improvement: Kaizen (PDCA/SDCA)

• Waste elimination, Lead-Time Reduction, Line & System Balancing

• Pull Systems/KANBAN

• 5S, Lean Metrics, Standardized Work, Visual Management, and Error Proofing Project Management

• Investment Casting, Extrusion, Forging, Stamping, Vacuum Brazing, CNC 5-axis machining, assembly lines design & Implementation, semi-conductor manufacturing technology

• Cost Reduction Projects

Professional Experience

ASML Jan 2020 – Present

Supplier Quality Manager

Main responsibilities include development and implementation of QMS at plant while collaborating with cross sectors development teams and high-tech suppliers to ensure alignment and timely execution of new product launch using ASML’s Agile Product Generation Process. Quality Initiatives and Results:

• Working in a fast paced and multidisciplinary development environment collaborate and bring together high-tech suppliers & the most creative minds in science and technology responsible for development of lithography machines that are key to producing faster, cheaper, more energy- efficient microchips. Integral part of the team that design, develop, integrate, market and service these advanced machines, which enable our customers - the world’s leading chipmakers - to reduce the size and increase the functionality of their microchips, which in turn leads to smaller, more powerful consumer electronics.

• Reduced supplier cost on a new EUV machine development project by 30% using Lean Sigma and Value Engineering workshops. Identified alternate low-cost material and optimized supplier manufacturing flow and internal assembly process.

• Reduced risk in supplier manufacturing processes by optimizing quality, testing and qualification infrastructure by using pFMEA’s and manufacturing flow analysis. Developed in-depth understanding of fabrication processes to estimate and drive manufacturing cost targets. Irfan Ahmad

128 Kennedy Drive Horseheads, NY 14845 607-***-**** *********@*****.*** Public

• Monitor and drive supplier yield and technical process improvements. Sponsor and participate in supplier improvement projects (e.g., cycle-time reduction, cost reduction, SPC Implementation, Lean Manufacturing and Operational Excellence).

BorgWarner Automotive NY Sep 2013 – Dec 2019

Quality Engineer, Staff

Active member of Program Management team responsible for new product launch for three major customers, Ford GM, and Subaru. Develop QMS, DFMEA, PFMEA, DCP, and Work Instructions. Manage supplier APQP and PPAP ensuring all supplied parts are robust, repeatable and conform to dimensional and performance requirements. Lead continuous process improvement projects to drive operational efficiency and execution of the supply base and prepare suppliers with the knowledge and support necessary for a flawless launch. Monitor performance and provide oversight of the entire supplier audit program. Lead ISO/IATF auditor. Develop and implement QMS and Lean Quality Tools. Quality Initiatives and Results:

• Developed, Implemented, and served as a gate keeper for the QMS system across four plants

• Collaborated with cross sector teams and suppliers to ensure timely ISO/TS certification.

• Liaised between design, manufacturing and executive teams as a contributor to development of CAM Phaser for Powertrain application. Ensured product manufacturability, robust design, compliance with regulatory requirements and transition from prototype to production ($20 million in sales in 2018).

• Reviewed PPAPs and obtained customer approval for New Product Launches with 100% on time completion.

• Conducted & maintained CQI-9 heat treat assessment for all global heat treat suppliers

• Conducted process mapping and time/capability studies to improve throughput by 36%, eliminate bottlenecks and ensured adherence to customer specifications.

• Lowered quality returns by 18%, saving $250K per year. Reduced number of customer complaints in half by providing robust & timely solutions to problems arising from suppliers, internal assembly processes, or at customer’s assembly plant.

• Increased sales by $290K in 2015 by developing a supplier-qualification program. Closed all outstanding CPM’s and issued 40% less CPM’s in 2019 as compared to the previous year.

• Incorporated Six Sigma methodologies to solve a range of design and manufacturing problems.

• Eliminated $450K in costs and reduced 55% defects by analyzing warranty data and implementing corrective actions utilizing, 8D, Six Sigma, and Shainin RedX tools at the Phaser Assembly plant.

• Participated in the development of suppliers by means of training, consulting and providing suggestions to improve their performance.

• Designed lean training program and facilitated Kaizen teams at Plant as well as at four major suppliers. Exceeded yearly targets for cost, quality, and delivery.

• Rolled out LPA (Layered Process Audit) program and ensured audits are completed on time, corrective actions/improvements identified are implemented and verified. Corning, Incorporated NY Apr 2001 – Aug 2013

Project Manager

• Led the design, fabrication, installation and start-up of the first two Gen 5 LCD (Liquid Crystal Display) glass auto-inspection lines at Corning’s new manufacturing facility in Beijing, China. This project enabled on-time full LCD glass sheet delivery to Chinese customers eliminating the packaging and express shipping costs from US-based operations. On-time delivery and faster response time led to rapid business growth in China.

• Completed multiple capital and process improvement projects in Japan, Korea, Taiwan, and China, satisfying the business strategy for growth and effectiveness in Asia Irfan Ahmad

128 Kennedy Drive Horseheads, NY 14845 607-***-**** *********@*****.*** Public

• Lead member of a cross-functional team who developed specialty optical fiber for mid and high temperature applications (oil and gas exploration). This development project was completed in 18 months (concept to final product delivery) utilizing Corning’s rigorous innovation methodology.

• Collaborated with site and division leadership to define cost improvement plans focusing on key performance factors characterizing process stabilization, waste elimination, and productivity improvement. Developed and executed CI (Continuous Improvement) plans to meet requirements set forth by the leadership in terms of CI activities completed and benefits realized.

• Consolidated and streamlined process flow at the Aerospace & Defense manufacturing facility in Keene, NH. Closed two low performing facilities, moved key equipment to Keene Plant, combined and streamlined processes enabling complete & efficient manufacturing under one roof. Achieved

$750K annual cost savings due to the improvement in manufacturing cycle-time, waste elimination, and labor cost reduction. The customer order lead time was reduced from 40 days to 18 days.

• Managed two equipment projects at the Canton, NY facility. Installed a glass annealing furnace and a EUV glass development lab. Both projects were completed ahead of schedule and within budget. This enabled in-house testing previously outsourced, saving the Canton plant over $700K annually.

Eaton/Cutler-Hammer (Unionized Facility) NY May 1998 – Apr 2001 Senior Quality Engineer / Lean SME

• Recognized by University of Tennessee as “Lean Systems Design and Implementation” expert for successfully applying Lean tools on various projects.

• Implemented Pull Production System in a Continuous Flow Manufacturing environment interfacing machining, subassembly, and final assembly through a very visible Kanban system. The outcome of the project was a 42% improvement in manufacturing cycle-time and a 55% reduction in WIP. These improvements directly impacted plant’s on-time shipment performance, which was enhanced to 99% from a 75% baseline in 1998.

• Supported plant leadership in instituting focus factory for two high runner products. Facilitated Kaizen teams to achieve & sustain continuous process improvements.

• Collaborated Kaizen, designed tooling and fixturing to support zero setup requirements, programmed CNC Lathes, Horizontal and Vertical Machining Centers for multiple operations. Other Experience:

• Senior Manufacturing Engineer - Ingersoll-Rand

• Manufacturing Engineer – Baker Hughes

Contact this candidate