Industrial/ Process Engineer

Harish Kumar Shetty

Education

University of North Dakota (Jan’05 – May’07), Master of Science in Industrial Engineering Technology GPA 4.0/4.0

Computer Skills

AutoCAD, Pro-E, Microsoft Office Suite, Oracle SQL/PLSQL, Oracle Manufacturing ERP, JD Edwards ERP Manufacturing-Supply Chain-Inventory & Order Processing, MS-Visio, Lotus Notes, ETQ, EPDM.

Overhead Door Corporation: Industrial Process Engineer (Jun’07 –Jul’09)

•Developed labor standards by analyzing work samples and methods; measured work performance, performed Time studies, Motion studies. Used Standard Work sheets, Standard work combination sheets for documenting the current status of work centers and floor operations.

•Improved labor utilization by studying work methods; tested modifications; designed new methods; recommended job restructuring with compliance of OSHA standards and ergonomics.

•Improved work flow by studying process flowcharts; recommended modifications in work flow, work stations, and product; developed new procedures; recommended equipment modifications and purchases. Created Engineering Approvals with a complete cost justification analysis.

•Reduced waste by studying methods, equipment, and operator techniques; recommended changes; established procedures to identify and analyze the 7 wastes. Created work instructions, Standard Operating Procedures and Quality Check sheets for Production lines to comply with company’s standards and customers expectations.

•Participated in the Packaging Project, which saved $200,000/yr. went through all the trials, RFQ’s, Floor studies, Writing Project reports, Presenting and getting it approved. The new Shrink Wrap Packaging machine packages 50ft/min and reduced the handling defects like dings and dents. Gave a new look to the doors, which created more customer satisfaction as it reduced the Returns and Allowances drastically.

•Implemented work improvement programs by conferring with management and engineering manager Created Maintenance Work orders and got the equipment modified for safety and to make a better quality product with less effort. Utilizing the concept of Work smarter not harder.

•Prepared work analysis reports by collecting, analyzing, and summarizing information and trends which helped us to understand the ground issues for deriving better results.Maintained industrial engineering data base by writing computer programs; entering and backing up data in JDE ERP system and also trained fellow co-workers with the engineering systems.

•Completed work improvement projects by training and guiding operators and supervisors. Maintained operation guidelines by writing and updating policies, procedures, and methods. Maintained professional and technical knowledge by attending/conducting SMED Events, Kaizen Events, Value Stream Maps, TPM sessions, 5S events, Safety meeting and Industrial Training Sessions.

•Created Scheduling/Forecasting reports for the production lines based on customer Orders, Equipment Capabilities, Machine history, Operator availability, Raw material availability and Preparation done by floor personnel for the orders to run the line with least cost and best quality.

•Reduced Lead times of vendor’s supplying parts and us delivering finished goods to customers by Initiating kaizen events, getting a day ahead of Production, Creating Min Max levels of On hand inventory, creating a discipline of Kanban and pull systems at both the ends.

•Reduced Inventory transaction errors by conducting regular Cycle counts on selected part numbers. Actively participated in quarterly Physical Inventories and solved all the high dollar variance errors both in positive and negative side. Corrected the JDE MRP system based on root cause investigations to prevent the errors.

•Standardized the Storage procedures, Warehouse management programs, retrieval procedures. This reduced the product searching time. Standardized the Shipping lane procedures, reducing the searching time by shipping personnel, which increased the loading time for containers. Worked with Shipping Supervisors to standardize the container cubing, reduced crating costs, Pallet costs and introduced pallet recycling program.

•Reduced System Issues by correcting Bills of Materials, Routings, conversion Factors, writing rules for Order Processing, creating tables for product offerings and setting up Branch Plant Item Master in JDE ERP system for adding new part numbers into systems.

•Reduced Costing Errors by correcting Overhead, Burden, Fixed and variable costs, Work center numbers, Labor rates and inventory relieving errors.

•Created a Visual Kanban Management for high demanding products, and which are run non scheduled lines. Disciplined the line and achieved good results which leaded to reduced inventory errors and eliminated the defined 7 lean wastes.

•Participated in 10+ Kaizen Events, many of which are focused on cost savings and safety improvements following the guidelines set by company and to be OSHA complaint.

•Conducted Audits for Safety, Productivity and Quality and issued Follow up plans to improve the score, Worked with the line personnel to achieve the goal set by the Auditor.

•Installed new product lines, Introduced new product offerings. Involved with the PPAP and FMEA, Design plans and Manufacturing plans before releasing the product. Created system support from Order entry to Order processing. Released PIB’s for distributor notifications. Completed the Installation qualification, Operation Qualification and Process verification of newly installed lines.

•Trained and supervised floor personnel about the new product offerings and explained the Manufacturing plans, case scenarios, expectations of management and mainly goals.

•Detailed the Windloaded doors, Standard doors, Corrected system based on orders

•Answered customer calls about installation issues, quality issues & cosmetic issues and processes the Returns and Allowances based on sales history and product cost. Reduced Overtime hours and created man-hour calculators to reduce labor dollars spent.

•Worked with Maintenance, created PM’s for the roll mills, Metal fabrication machinery and general equipment. Troubleshooting during breakdowns and creating procedures from happening again.

•Reduced the raw material usage by consolidating and finding alternatives as 60% of our cost is raw material. Submitted Design changes to make Universal parts, which can be used on multiple products.

•Submitted Engineering Changes, Engineering Notices, Engineering Requests. Created and modified drawings with the changes for submittal process.

•Used the Excellence through Quality system for addressing Quality issues arising from Manufacturing Process. Based on the corrective actions, changed the process eliminating QC issues.

•Used SPC, Fishbone diagrams, CpK, Gage R & R, Fault tree analysis, and all Lean/Industrial Engineering & Six Sigma tools to determine the influencing factors of defects.

•Trained in Six Sigma Green Belt Program and submitted projects

•Written and submitted Engineering Approvals, Project Charters. Presented to Management for approvals with complete cost justification analysis.

•Visited jobsites helping Distributors/installers in installing doors, answering end customer issues and releasing Public Information Notices to present the new offerings and answering the technical questions and fix field issues on site.

•Made special doors, Special tracks and packed special hardware for nonstandard offerings of products, manually calculated the cost of these special doors. Worked with JDE ERP rule writer to create rules for calling parts on Work orders and created formulas for quantities of parts to be called.

•Created plant drawings for new equipment installations, Floor availability studies and for municipal tax purposes.

•Created Fire watch program and Lock out Tag out procedures for the plant

•Reduced the Scrap coming out of production lines by creating procedures of scrap reporting, issuing new scrap codes and identified the scrap generation causes/source and reduced them.

•Documented OEE data for Project tracking purposes and for better understanding of before and after picture.

•Audited departments for 5S, Issued action plans and 3W lists for better score reporting.

•Learned on how to deal with employees in the Union environment.

Bobcat, Ingersoll Rand: Lean Manufacturing Engineer (Jan’06 – Aug’06)

•Participated in 30+ Kaizen events. Teams included 6 or more people with different backgrounds. Gave pre-kaizen training about the problem and corrective action planning.

•Taught 5S and Lean Concepts to Team members and made brought them to same pace.

•Collected all the Pre Kaizen data, which includes using all the standard Industrial Engineering tools. Documented and Presented to Team members. During the course of the event, Worked with various teams on improvement action items, helped implementing the action items for faster results. After the events, Worked with Team leaders for finishing the projects, giving them the resources and closing the projects with a good cost saving note.

•Worked with Menlo World Wide Supply Chain Company which stocks all the 6000+ parts which are used on the production lines to develop and implement a PULL system by which we only had 2hrs worth of inventory on hand. This reduced the premium floor space.

•Created a Plan for Every Part plan, which eliminates the handling defects and better delivery to the floor.

•Created KITS for operators, KITS consisted of parts as per Bills of Materials for that specific operation, This reduced the Quality issues and also speeded the cycle time, reducing the confusion and standardized the assembly steps

•Created and Maintained Supermarkets, These Supermarkets consisted of parts for KITS as per the sequence and are filled by the Milk Runners per supervisor’s request. This reduced all the non value added walking time and improved the cycle times.

•Introduced MOVING PRODUCTION LINE concept into the model 435 excavators, production went up from 3 units/shift to 4.5 units/shift. Implemented Pull concept and introduced pace into the work area.

•Updated Takt time boards for every department with daily production goals/hr, Worked with department managers in finding the demand for the shift for using in Takt calculations.

•Worked with Sensei (Mr.Oba) in solving complex issues arising during Kaizen events.

•Created a LEAN office layout, making the departments more ergonomic and efficient.

•Changed the Daily morning meeting pattern and reduced the meeting time from 45mins to 20mins. Focusing on Production, Cost, Safety and Quality.

In charge for the Moonshine lab, where all the experiments, tool building, work area modifications, Carts, Vices, Jigs and Fixtures were created. Inventoried all the parts, designed using CAD and helped building the parts.

•Conducted DOE on the Quality audits and zeroed down on the Root cause.

•Conducted Audits on the finished products, changed the Audit sheets to reflect the current problems, issues and followed up line supervisors. Created a Finished Goods Layout, which reduced the searching time for Shipping personnel, Standardized the Shipping Procedures and Material handling.

•Created Value Stream Maps for all the Products manufactured in the Bismarck location.

•Performed Ergonomic assessment of work stations and work centers.

University of North Dakota: Lean Manufacturing/Teaching Assistant (Jan’05-Dec’05)

•Member of Lean Thinking Group, Implementing Lean in the Department and in the University

•Supervised and trained 50+ students in the manufacturing technology lab about the manufacturing process and Manufacturing software’s.

•Maintained the complete Manufacturing Technology Lab consisting of Lathes, Mills, Drilling machines, Metrology, Paint lab, Wood working machines and Furnace. Conducted classes for the Undergraduate students in the industrial technology classes. Created Value Stream Maps of the department enrollment process, which helped students understand the process involved. Conducted Tuition classes for Mathematics and Statistics

Reference:

Professional references available upon request.

Misc.:

I am willing to relocate on my own, Work any shift, Work any number of hours and will earn my salary by showing savings worth twice my salary.

Thank for your valuable time for reading till end.

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