Engineer Process Improvement

SHYAM VELUMANI

Farmington Hills, Michigan

313-***-**** / *********@*****.***

SUMMARY

• Consistently delivering problem solving innovations with a unique mix of lean proficiency, operational excellence and Six Sigma Green Belt expertise

• Extensive Simulation and Optimization knowledge with track record of improving efficiency, utilizations and cutting costs

• 4+ years of process improvement experience in high profile organizations in various fields from automotive to healthcare

PROFESSIONAL EXPERIENCE

Department of Veterans Affairs Medical Center [VAMC]

Jun’10 – Present

Industrial Engineer

• Hired as an Industrial Engineer to establish metrics, implement lean and continuous process improvement techniques at the hospital which was facing long patient wait-times and low utilization factor

• Develop sterilization/production standards using time and motion study to improve efficiency and throughput

• Prepare project proposal identifying metrics, goals, deliverables, time-line, capacity resource analysis and costing

• Documentation of the sterilization area in preparing Standard Work Instruction, Visual aids and Bill of Materials

• Analysis to determine the Optimal resource level and staff utilization using optimization models

• Analysis using Minitab to identify the distribution pattern of the data sets and carry-out regression analysis

• Perform PDCA and PFMEA to analyze failures of an existing process

Operational Management Optimization in Sterilization Department [SPD]

• Operation Room [OR] was suffering from appointment cancellations and delays because of instrument unavailability from SPD

• Value Stream mapping of Instruments from clinics to Sterilization department and back to point-of-use

• Simulation model built with Visual Basics coding in Arena is used to determine the delays in Instruments availability for use in OR and clinics

• Designed and developed a prioritization algorithm which helps in sequencing the instruments coming into sterilization for cleaning

• Accomplishments: Reduced the appointment delays in OR by 25% and integration with Operation Room simulation model for optimized surgery schedules

Patient waiting time reduction in Emergency Department [ED]

• Developed discrete event simulation model to identify the optimal mix of resources in Emergency Department to reduce patient waiting time

• Analysis on patient wait time by varying the resource level at different time of the day

• OptQuest optimization with simulation model was used to determine the optimal resource schedule

• Accomplishments: More physicians in peak hours and combined nurse stations proved to reduce patient waiting time to less than 8%

• Saved more than million to the hospital from hiring more physician

Sam’s Club Distribution Center

Jan’10 – May’10

Simulation Analyst

• Core strategic team member responsible for increasing the productivity of the distribution center where the layout and movement of material handlers were disorganized and random

• Disorganized and random movement of material handlers led to non-value added processes resulting in unattainable productivity

• Cellular manufacturing methodology was applied to the distribution center with assigned material handlers for each cell and the new layout was mapped in AutoCAD

• Discrete event simulation model was developed to study the impact of new layout on productivity and efficiency

• Accomplishments: Stream lined the material movement process and improved the productivity by 12% with cellular layout

Goodwill Industries of Greater Detroit

Sept’08 – Dec‘09

Industrial Engineer Intern

• As an Industrial Engineer Intern was responsible for generating inventory management strategies, implement lean manufacturing technique and lead cross-functional improvement teams at the plant level

• Executed inventory management techniques at a plant that was facing high inventory levels of finished parts

• Implemented a Kanban Pull system to link (a) accurate orders from market place, and (b) production cells to finished goods

• Implemented 5S and Day Warehouse system on the shop floor for better visual management

• Increased throughput of the production cells by identifying bottleneck and line balancing

• Designed a live tool to graphically represent the continuous changing status of shop floor production and inventory

• Developed a production scheduling strategy and built two production scheduling tools in Access: BTS (Built to Schedule) and DPS (Daily Production Schedule)

• Accomplishments: Production scheduling tool increased the demand satisfaction metric from 78% to target 90%

• Kanban system and inventory tool helped reduce finished goods inventory level to less than 10%

Sree Annapoorna Foods

Jun’07 – Jul’08

Program Analyst

• Optimize administrative infrastructure and deploy rapid implementation of OSE techniques when the company was facing high penalties for unmet customer demands and customer satisfaction

• Responsible for applying Operation Research concepts at plant which was experiencing chaos in job scheduling

• Developed an optimization model for daily activity of scheduling jobs to machines with Premium Solver for ease of use and maximum flexibility

• Assisted production manager in supervising shop floor activities and daily production

• Accomplishments: Improved machine utilization and increased the productivity by 20% with same labor utilization

Epinger Tooling Asia Ltd

Apr’06 – Aug’06

Engineering Internship

• Develop Machine Scheduling Program using VB, based on Ant Colony algorithm for assignment of jobs

• Design fixtures and built prototypes of fixtures to validate the design before production

EDUCATION

Masters in Industrial Engineering (GPA - 3.62)

May 2010

Wayne State University, Michigan

Bachelors in Mechanical Engineering (GPA - 3.45)

May 2007

Anna University, Chennai, India

ACADEMIC PROJECTS

Auto/Con Corp: Simulation Modeling & Lean operations

• Detailed study of resources utilization, cycle time and simulated the changes to processes and reduced the cycle time by 30%

• Achieved organized system, well defined processes & efficient standard of work through implementation of lean

DTE Energy: Optimization of component distribution system:

• Reduce inventory levels at distribution centers and minimize the distance trucks have to travel with maximum capacity

• Combined locations to form zones and assigned a distribution center to each zone using linear programming optimization

• Route for trucks to travel everyday within the zone was mapped using a Transportation route model

COMPUTER SKILLS

• ARENA, ProModel, Simio, MATLAB, Premium Solver, Opt QUEST, Minitab, AutoCAD, ERP System (AIM)

• Visual Basics, Excel Programming, MS Access, MS Visio and MS office suites

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