Industrial Engineer - Lean Six Sigma Green Belt Senior Leader
Resume:
F K
Furqhan Abdul Khader
Professional Summary
Results-driven Industrial Engineer and Certified Lean Six Sigma Green Belt with over 6 years of expertise in optimizing warehouse operations, labor productivity, and supply chain processes across logistics, distribution and manufacturing sectors. Proven success in implementing engineered labor standards (ELS), driving continuous improvement initiatives, and enhancing inventory accuracy through Lean Six Sigma methodologies, time studies (MOST), and advanced analytics tools such as Power BI, SQL, Excel, and Python. Proficient in WMS implementation, warehouse layout optimization, and automation projects, consistently achieving multi-million-dollar cost savings and significant productivity gains for over 15 warehousing and distribution clients. Strong advocate for cross-functional collaboration that fosters innovation and efficiency in operational processes.
Work History
Midwest Goods Inc - Senior Industrial Engineer
Chicago, IL
10/2023 - Current
Conducted comprehensive time and motion studies (MOST) across all warehouse departments to identify labor standards, determine root causes of inefficiencies, and develop, validate, and maintain sustainable time-studied standards.
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Implemented slotting optimization, bin movement automation, heat maps, and batch/zone picking strategies, improving picking efficiency and reducing labor costs by 25%.
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Identified system and process failures, implemented and maintained CAPA documentation, and streamlined workflows through Value Stream Mapping and team training to sustain continuous improvement.
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Developed Arena simulations for inventory and shipping processes and conducted audits and comparative site analyses to optimize resource allocation, identify performance gaps, manage operational risks, improve predictability, and establish benchmarks for inventory control excellence.
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Led conveyor automation and warehouse layout redesign to optimize material flow, increase throughput and accuracy, and reduce manual handling time — achieving a 20% reduction in process waste through
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******************@*****.***
Chicago IL
LinkedIn Profile
● https://www.linkedin.com/in/fkhader/
SKILLS
● Time & Motion Studies (MOST)
● Engineered Labor Standards (ELS)
● Labor Management Systems (LMS)
Process Mapping & Value Stream
Mapping (VSM)
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Continuous Process Improvement &
Lean Six Sigma (5S, Kaizen, Standard
Work)
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Root Cause Analysis & Problem
Solving (FMEA, SPC)
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Slotting, Layout Optimization,
Workflow Design
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Inventory Control & Warehouse
Productivity Analysis
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Warehouse Management Systems
(WMS)
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● Inventory Management Systems (IMS)
Power BI / KPI Dashboards / Data
Visualization
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Deloitte Consulting - Consultant Supply Chain Network Operations Chicago, IL
09/2021 - 10/2023
Alpine Supply Chain Solutions - Supply Chain Data Analyst St. Charles, IL
01/2021 - 07/2021
Lean Six Sigma methodologies such as 5S, Kanban, Kaizen, and standard work instructions.
Developed interactive Power BI dashboards and standardized SOPs to track labor, operational, and QHSE KPIs — including productivity, order accuracy, inventory control, and safety compliance — enabling real-time visibility and data-driven decisions that improved labor efficiency by 15% and order accuracy by 12%.
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Introduced RF scanning technology and handheld devices to digitize inventory tracking and customer order fulfillment, driving a 30% reduction in shrinkage and significant gains in labor efficiency and inventory control accuracy.
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Secured $2M+ in annual transportation savings by optimizing the logistics network and renegotiating carrier contracts to improve service performance and cost efficiency across distribution sites.
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Led warehouse process improvement and supply chain projects across multiple distribution centers, implementing automation, layout redesigns, and workflow optimization to improve labor productivity and inventory control.
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Managed end-to-end WMS implementations, including gathering site requirements, evaluating vendors, conducting testing, and overseeing go-live, enhancing labor management, operational efficiency, and inventory accuracy by over 40%.
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Developed and applied a Capability Maturity Model (People, Process, Technology) to assess distribution center performance, identify gaps, and recommend continuous improvement initiatives in labor, productivity, and inventory control.
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Applied industrial engineering principles to conduct As-Is and To-Be process mapping, time studies (MOST), and engineered labor standards, optimizing workflows, reducing waste, and establishing sustainable productivity benchmarks.
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Managed cross-functional continuous improvement projects, coordinating operations, engineering, and IT teams, documenting requirements, and implementing corrective actions to ensure on-time delivery and measurable performance gains.
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Directed CAPEX and OPEX initiatives for material handling equipment, automation, and layout redesigns, evaluating system requirements, implementing solutions, and achieving cost savings while sustaining operational improvements.
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Led productivity and process optimization projects across multiple distribution centers, including Best Practice Assessments (BPA), Storage Type Analyses (STA), Slotting, and Strategic Master Planning (SMP),
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SQL, Python, Excel for Analysis and
Customization
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● CAPEX & OPEX Project Execution
Change Management & Process
Adoption
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Cross-Functional Collaboration /
Stakeholder Management
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● SOP Development & Documentation
Facility Layout Planning & Space
Optimization
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● MS Project / Agile / Scrum / Kanban
● AutoCAD / SolidWorks
● Vendor & Contract Negotiation
● Labor Planning and Scheduling
● Arena Process Simulation Application
● Risk Management
● Project and Time Management
Education
Northern Illinois University
DeKalb, IL
Master of Science: Industrial And System
Engineering
Osmania University
Hyderabad, India
Bachelor of Science: Mechanical
Engineering
Certifications
● Certified Lean Six Sigma Green Belt
● Certified Data/Business Analyst
● Certified CAD Designer
SD Wheel - Industrial Engineer Intern
Batavia, IL
01/2020 - 01/2021
delivering measurable improvements in throughput, labor efficiency, and cost reduction.
Developed interactive Power BI dashboards to visualize labor, inventory, and service KPIs, enabling real-time monitoring, data-driven decision-making, and continuous improvement at the site and executive levels.
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Directed facility layout and design optimization initiatives, producing AutoCAD-based layouts, distribution network analyses, and equipment specifications that improved material flow, scalability, and warehouse utilization.
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Designed and evaluated racking and MHE systems for CAPEX projects, performing detailed capacity analysis, flow simulations, and ROI evaluations to ensure safe, cost-effective, and high-performance operations.
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Applied industrial engineering and Lean Six Sigma methodologies to optimize slotting, workflow, and labor allocation — achieving productivity gains exceeding 50% across client facilities.
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Partnered with warehouse operations and cross-functional teams to identify process bottlenecks, conduct time studies (MOST), and implement standardized work and continuous improvement practices that enhanced efficiency, reduced waste, and sustained long-term performance.
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Reduced assembly and warehouse cycle times by 40% and increased throughput by 30% by applying Lean Six Sigma and smart manufacturing principles to optimize workflows, workstation design, and labor allocation.
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Automated quality control, labor planning, and warehouse processes, improving QA efficiency by 40%, order accuracy by 20%, and standardizing workflows for scalability across sites.
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Performed line balancing and time studies (MOST) on the warehouse floor, identifying root causes of inefficiencies, optimizing manpower utilization, reducing idle time, and aligning operations with productivity targets.
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Designed optimized warehouse layouts and workstation setups using AutoCAD, enhancing ergonomics, material flow, safety compliance, and sustaining continuous improvement through PFMEA and control plan recommendations.
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Led multiple CAPEX and digital transformation projects, including automation, MHE upgrades, and data-driven process improvements, delivering measurable ROI and long-term operational efficiency.
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Created scheduling tools to capture work content, standardize labor planning, and improve workforce productivity across warehouse operations.
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