Six Sigma Engineer

ABDUL QADEEM

**** ******** **** # *** **********, TN 38138 901-***-**** **********@*****.***

Lean Six Sigma & Operational Excellence Professional

Results-oriented professional with more than 8 years of experience to dramatically improve an organization’s bottom line through disciplined execution of lean and six sigma tools.

Lean Six Sigma Black Belt Certified from Advanced Integrated Technology (AIT)

Experience in manufacturing of motion and control technologies, hybrid drive systems, power distribution units & medical devices.

MS in Mechanical and Industrial Systems Engineering with solid leadership experience.

Key Skills

Lean Six Sigma

Lean Transformations

DFM/DFA/DFSS

Project Management

PFMEA Change Management

Value Stream Mapping

TPS & 3P

Pull Systems

Production Control Plan Process-oriented

Continuous flow & SMED

Facilitate cross-functional teams

CAD/CAM

Error Proofing

Experience

PARKAR HANNIFIN, HYBRID DRIVE SYSTEMS 2008-Present

Parker’s Runwise system replaces a refuse truck’s conventional drive train with a series hybrid drive system that marries the variable features of a hydrostatic drive for urban routes during refuse collection with a mechanical drive for efficient operation at highway speeds.

Manufacturing Development Engineer/Lean Deployment Leader, Operational Excellence

• Designed and executed the complex hydraulic hybrid energy recovery assembly line with Toyota production systems and Production preparation process.

• Successfully launched the product on time to the market with state of the art assembly line which included operator guidance system, error proofing techniques, cycle time traceability, operator traceability, component traceability, automated lean, process and quality systems, variable data gathering to help with assembly line balancing and employee performance metrics.

• Implemented PFMEA, Process flow, Production control plan, Plan for every part, SOP’s, super market for purchased components, capability studies, GR & R, SPC and receiving inspection plan.

• Established built in reliability into manufacturing and assembly and increased the fleet uptime of the Refuse trucks from 50% to 98%.

• Defined prevention controls for 5329 potential failure modes with multiple gates and poke yokes in the assembly line.

• Increased MTBF (Mean time between failures) of manufacturing reliability by almost 50% closer to design and testing reliability.

• Expertise in using Statistical software Mini Tab to reduce variation and defects to improve process capability index and reliability.

• Led high performance work team during the launch coaching them on LEAN/Six Sigma philosophy implementation for the plant in high-impact projects.

PARKAR HANNIFIN, CHELSEA PRODUCTS DIVISION 2005-2008

Parkers Chelsea Power Take off division has been serving the auxiliary power market since 1945 with the broadest coverage in the industry

Manufacturing Engineer/Value Stream Lean Leader, Operational Excellence

• Kanban calculations and PFEP (Plan for Every Part) for runners, repeaters and strangers in the machining value stream.

• Established milk runs with top 10 suppliers impacting inventory dollars and also reducing stock-outs on purchased goods inventory.

• Championed entire machining layouts, assembly line layouts, supermarket layouts to increase visibility, improve customer service, productivity; reduce RPPM by separating value added and non-value added elements.

• Finished a Lean Six Sigma project to reduce customer complaints in PBP area and also performed DOE to improve productivity of shafts and gear.

• Reduced inventory from 45 days to 25 days with a developed optimizer in machining with major dollar impact just on runners.

• Received comprehensive training on Lean boot Camp I, II, III, Lean Six Sigma, Toyota Production Systems, 3P Process etc.

• Led numerous Kaizan events in machining value stream and was successfully able to increase the OEE of multiple cells.

• Implemented internal Kanban in finish machining and green machining to optimize machining value stream and reduce inventory of finish goods supermarket and WIP.

• Created electronic Kanban in machining to help procurement with suppliers inside and outside the country which is extensively being used on day to day basis.

• Reduced setup time from 25 minutes to 10 minutes by improving the processes, speeding up program cycle times and continuously striving for improvements to reduce setup time to SMED.

• Increased efficiency of the cells and increased Pieces/Labor hr from 31 to 53.

• Supervised and Championed finish machining team on cost reduction projects and saved company approximately $500,000/yr on engineering changes.

• Reduced tooling cost per part from $1.35 to $.25 by implementing harmonic and vibration analysis to study tool wear and tear and optimize speeds and feeds.

• Expert in Parkers House of Lean, Value stream Maps, Six Sigma methodologies.

• Layout machines to improve uptime of the machines and utilize labor & capacity properly using 3P process. Assist with quality control objectives and activities such as design, standardization of parts.

• Applying statistical methods and perform mathematical calculations to determine manufacturing processes, staff requirements and production standards.

• Eliminated waste and trouble shoot problems by implementing PDCA, Team Improvement Boards, Day by hour boards, A3 Boards etc.

• Implemented lean principles such as Value stream mapping, Demand Flow, Single Piece Flow, Five S’s, Visual Management, Total productive maintenance, Continuous Improvement Process, Kaizen, SPC and Statistical Problem Solving

P.A.C.T Manufacturing, Manufacturing/ Design Engineer, Memphis: APR 04 SEP 05

• Engineered all the projects from design phase through manufacturing for manufacture of Orthopedic Implants, Surgical and trauma instruments using ESPIRIT software’s on multi axes CNC machines for Smith and Nephew, Wright Medical Technology and Medtronic Sofamor Danek.

Converting the CAD designs into .dxf and .src files and design the part geometry in ESPRIT or Master Cam keeping in mind the stock for metal finishing, bending allowance and any other QA specification.

Writing 4-axis and 5-axis Fanuc Programming for Mill lathe and wire EDM’s.

Developed and implemented improvement of new and existing process flows to optimize product yield and cycle times.

Develop and maintain manufacturing outlines, assessing and implementing changes, updating drawings, carrying out cost savings programs, designing production fixtures and jigs, writing and illustrating user manuals and technical customer support.

Shop floor process prove out of the design and mill, wire and lathe programs on various CNC machines like HASS, MORISEIKI, HARDINGE, OKUMA, MITSUBISHI, FANUC EDM, COBRA AND HARDINGE LATHE.

Creating Over-Lays with the given tolerance and interface with QA department to solve production problems

Recommends and procures new capital equipment to support production.

Supports training of production floor personnel in the use of new work instructions, processes or tools where necessary.

Expertise in using Statistical software Mini Tab to reduce variation in almost every process ranging from production, manufacturing, quality, assembly, packaging and shipping.

Interfaces with outside vendors on technical issues associated with product quality and manufacturability.

Provides general Manufacturing Engineering technical support to daily manufacturing operations.

Creating and maintaining CAD drawing templates. Writing company SOPs for using CAD applications.

Education

University of Memphis, Memphis TN 2003

Masters in Industrial and Systems Engineering (3.7 GPA)

University of Memphis, Memphis TN 2001

Masters in Mechanical Engineering (3.8 GPA)

Osmania University, India 2000

Bachelors in Mechanical Engineering

Technical Skills

• Lean Tools: Value Stream Mapping, Kaizan, Pull Systems, PFEP, Andon, Standard Work, Takt time planning, Error proofing, Automatic Stops, Quality control, Quick change over, Takt time planning, Standard work combination charts, TIB, Site Matrix, 3P Process, TPM, TPS, Visual controls, Continuous Flow, FIFO, SMED.

• CAD software’s: Pro-E Wild Fire, AutoCAD, Auto Desk Inventor

• CAM software’s: Esprit, Master Cam.

• FEA: ANSYS, Pro-Mechanica

• Programming Languages: 4 and 5 axis Fanuc Programming, VC++, and VB6.0

• Statistical tools: Cplex, Minitab, SAS, Lindo, Lingo, Excel, SQL.

• Simulation software’s: Arena, Enterprise Dynamics.

• Others: MS Office, MS Excel, Macros, Visual Basic Editor, Mat lab, Fanuc Programming.

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