Manufacturing Manager

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SUMMARY________________________________________

Certified Six Sigma Black Belt with a Masters degree in Industrial Engineering, looking for Full-time or Internship opportunity in the areas of Manufacturing, Quality Systems, Production or Supply Chain in a multinational corporation. One and a half years experience in Quality Assurance, Root Cause Analysis, Inventory Control and Supply Chain Operations. Self motivated, Team player, proven quantitative and analytical skills with good interpersonal capability and an ability to work cross functionally.

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SKILLS

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 Quality / Statistical: Six Sigma Quality, Design and Analysis of Experiments, Statistical Process Control.

 Operations Research / Mathematical: Linear Programming, Stochastic Methods, and Discrete Optimization.

 Other Areas: Production Planning, Supply Chain & Logistics, Demand Forecasting, Inventory Control.

 Software: Minitab (Statistics), OPL-CPLEX (Optimization), ARENA (Simulation), Matlab, C, JAVA.

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EXPERIENCE

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Six Sigma Black Belt Certification

Saint-Gobain Ceramics, Niagara Falls, NY

October 2009 – May 2010 (7 months)

Current Project Title: Quality Improvement of the Premix Shrinkage using Six Sigma Methodology (DMAIC).

Description:

 Define Phase: Developed a Project Charter by Defining Problem statement, Goal statement, Project Scope, Project timeline, financial impact and bounds of the project through SIPOC chart.

 Measure Phase: Prepared a Macro level Process Mapping and Cause and Effect diagram by understanding the process and Established measurement plans for KPIs and KPOs and performed Gage R&R on Beckman Coulter instrument. Studied the capabilities of process using Ppk for the past 3 years.

 Analyze Phase: Identified the critical few KPIs affecting the KPOs through FMEA, Brainstorming and by using Statistical Analysis tools such as Step-wise Regression, Generalized Linear Model and ANOVA.

 Improve Phase: Conducted Design of Experiments (DOE) using Central Composite Design to confirm the identity of the root cause. Calculated Optimized levels of KPIs using Response Surface Methodology. Maintained KPIs within these optimized ranges in order to get the output variable within the tolerance levels.

 Control Phase: Improvement led to an increase in process performance Ppk and its significance was tested using t-hypothesis test. Provided Control plan documentation to make sure that the critical variables are operated within the optimized levels continuously.

Internship

Bharat Forge Limited, India

January 2008 – June 2008 (6 months)

(1) Title: Inventory Control of manufacturing tools in materials department.

Description:

 Worked in a team consisting of employees from purchasing, inventory, production planning and control and IT departments.

 Categorized manufacturing tools using ABC analysis based on the annual consumption value.

 Forecasted demand for the A category tools based on the historical consumption data using Exponential smoothing and Holt's method (considering trend).

 Compared the forecast performance of these methods with previously followed Moving Average method using MAD, MAPE and MSE.

 Updated the Economic Order Quantity (EOQ), Safety Stock and Re-order point based on these forecasts which lead to 7% increase in Service level.

(2) Title: Re-evaluation of subcontractors performing basic machining operations of the company.

Description:

 Was part of a team involving employees from Materials, Quality assurance department, Machining components division and Heavy forging division.

 Determined the key improvement areas such as cost, quality, lead time, responsiveness and order status where subcontractors needed to align themselves with company’s objectives.

 Performed sub-contractor on-site audits to evaluate their business practices and provided scorecards by benchmarking them with company's standards.

 Provided actionable feedback to the suppliers for continuous improvement.

Internship

General Motors India Pvt.Ltd, India.

July 2007 – December 2007 (6 months)

Title: Quality Control of problems related to:

1.) Rear Bumper to Quarter Panel flushness in a vehicle model (Tavera) using RED X technical problem solving strategy.

2.) Fender to Headlamp fouling in a vehicle model (Spark) using RED X technical problem solving strategy.

Description:

 Worked in a cross-functional team of 5 involving Red X Master and Journeymen from Quality, Product Engineering and Manufacturing departments.

 Identified the root cause (Red X) of the problem through Shainin tools such as Best of the Best (BOB) vs. Worst of the worst (WOW), Multi-vari charts and Defect concentration charts and brought to the notice of the Process owner.

 Validated the variable gage using Measurement System Analysis.

 Executed Design of Experiments to confirm the identity of root cause (Red X).

 Worked with Supplier Quality Assurance department to bring the non-conforming fixture of supplier used to manufacture the defective part, in-line with the GM gage/fixture standards which lead to the reduction of DPMO and an increase in process yield by 21%.

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EDUCATION

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State University of New York College at Buffalo

Master of Science Industrial Engineering (Specializing in Quality Control & Operations Research)

2008 – 2010

CGPA: 3.501/4

Courses:

Six Sigma Quality, Design of Experiments, Quality Assurance, Supply chain & Global operations, Production Planning & Control, Linear Programming, Discrete Optimization, Stochastic Methods, Simulation & Stochastic Models, Human Factors in Safety.

AcademicProjects:

1.) Variance reduction in Range and straightness of the Catapult projectile following Six Sigma methodology.

2.) Evaluating and providing recommendations for the Evacuation process of Shores and Island during emergency exit using Simulation and Stochastic methods and ARENA.

3.) Forecasting Demand and Controlling Inventory accordingly at Harriman Dining Hall (Campus Dining Center at SUNY-Buffalo)

Birla Institute of Technology and Science

Bachelor of Engineering (Hons) Mechanical +Master of Science (Hons) Mathematics

2002 – 2008

Related Electives:

Production Planning and Control, Quality Control Assurance & Reliability, Flexible Manufacturing Systems, Operations Research, Optimization.

Academic Projects:

A computer oriented Project on 'Mathematical Formulation of Heat Transfer in Continuous Casting.

PapersPresented:

Presented a Technical Paper on 'Numerical Simulation of Heat Transfer in Continuous Casting Process 'at national level during APOGEE-2007(Technical Fest held at BITS, Pilani).

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CERTIFICATIONS

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 Six Sigma Black Belt: Certified by The State University of New York at Buffalo for successfully completing a Six Sigma project at Saint Gobain Ceramics, Niagara Falls, NY in May 2010.

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WORK AUTHORIZATION

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 Work Authorization: Authorized to work in US temporarily for upto a maximum of 29 months on F-1 OPT (Optional Practical Training) status starting from July 15th 2010.

Requires Sponsorship of H1-B visa in future.

 Availability: Immediate.

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