Engineer Manufacturing

Manjunath Subbaiah *********@*****.***

***** ******** ****** **** ***** CA 90706 818-***-****

PROFILE

Manufacturing/Industrial Engineer and Mechanical Engineer with MS in Manufacturing Engineering focus Manufacturing and process, production improvement enhancing productivity using techniques such as Lean manufacturing and six sigma quality management.

Design Software - Solid Works, Auto CADD, CAD/CAM, BOM, MPS and MRP.

Production Lean Expertise - TPS ( Toyota production system), 5S, Kanban, JIT, VSM, Problem solving TBP (Toyota business practice), 8D, One piece flow six sigma quality tools like DMAIC, PFMEA, PDCA, Root Cause Analysis, SPC, Cpk and Gauge R&R to provide corrective actions that emphasize on continuous improvement (Kaizen).

Manufacturing Engineering/Industrial Engineering (Lean)

Experience Planning, directing production and resolving production issues and material defects provide corrective and preventive action of product assembly lines with quality control and define product specifications for manufacturability.

Strong tie to internal and external Customers, vendors to effectively drive achievement of production needs, material and equipment and solid understanding of the Demand/Supply Chain Process , on time delivery(OTD)

Managing and Planning projects from start to finish by meeting customer demands utilizing work force, space requirements, workflow requirements, validating process, engineering requirements.

Manage meeting to implement successful changes to drive the company goals and standards.

Improve performance of equipment and process (TPM) by optimizing and track data for improvement and driving setup time, cycle time down and increasing machine capability and capacity and uptime up to 100%.

Actively involved in projects in support of business objectives: cost reductions, inventory reduction initiatives, lead - time reduction, lean manufacturing and 8D problem solving Problem solving (TBP Toyota business practice), 5Y and 6-sigma (Fishbone), gauge R&R at a senior level and following implementing pokayoke.

Experience in Provide technical direction and support to the manufacturing floor staff including team leaders for new and existing improved process to increase productivity and write SOP’s for new process.

Compliance with company standards to maintain up to date documents for audits and future reference.

Experience in initiating kaizen events and make improvements on the process and share the improvement(yakoten) to all the departments where applicable and maintain change point management for awareness of change

Draw Value stream maps, process maps eliminated waste from process and improved on lead time, cycle times

Meet the daily demand by maintain takt time and reducing the driving cycle time down to meet the daily target demand

Involved in cross training team members, operators on new and changed processes, SW, PIS (Process instruction sheets)

Understand and be able to apply Lean 6 Sigma in order to achieve complete customer satisfaction through process improvements and identifying KPI’s to drive safety, Quality, productivity and cost(SQPC) activity boards

Product Design Engineering

Experience in designing and developing new product to customer requirements, DFM, develop prototype, test and release drawings, blueprints to production interacted with manufacturing for changes in tooling and fixtures

Experience in designing tooling and fixtures using GD&T for improved production efficiency and continuously improve on process by reducing cycle time and maintaining takt time and balancing the line as required.

Experience in evaluating, improving, developing quality manufacturing methods for new and existing products (ECI), ECR and BOM creation in MRP, create new routings for BOM part, planning for production.

Talk to customers regularly for change in product requirements ECN/ECI/ECO and process and communicate to engineering, production, quality, design for feasibility to manufacture and meet customer demands regularly.

Experience in developing line layout to assemble parts, testing and to promote smooth flow of products to manufacturing assembly, drawing layout for equipment, parts routing and OTD to customer of new products.

Interface with planning, quality control, R&D to improve product, material, process for introduction of new products and setting up process (process validation) to manufacture quality and defect free Material for welding, assembly process

Experience in Coordinating with suppliers for right material, quantity arrives for production and final material approval MRB, demand planning strategies and organization goals of on-time production, Track EH&S.

TECHNICAL

Design software’s: Solid works 2009/2010/2011, Ansys, Auto CADD, Master CAM, ISO 9001, ASME.

Equipment’s used: CNC 3 and 4-AxisVMC, HMC, 7-Axis turning centers, CNC Lathes.

Operating system: Windows all Versions, MAC OS.

Other Tools: MS Access, MS Visio, MS Project, Minitab 16, PLC RS Logix 1200, MS Office , Lotus Notes.

ERP: e-Kanban ERP, BOS (Body weld operating system), FMS (Field Management System), E-payment, PeopleSoft, TEMA mainframe, UALC (Unit Assembly line Control).

CAREER PROGRESSION

TABC, Inc (Toyota Auto Body California), California - (Feb. 2011 – Present)

Manufacturing Engineer

TABC produces sheet metal components, steering columns, catalytic converters, coated catalytic substrates, and sub-assemblies for Toyota’s North American manufacturing facilities and for export to Japan.

Responsibilities

Experience in designing and developing new product to customer requirements, DFM, develop prototype, test and release drawings, blueprints to production interacted with manufacturing for changes in tooling and fixtures.

Responsible for analyzing and creating standard operating procedures (SOP’s) for new projects with cost reduction, develop and document process flow charts for new and existing product lines,5S Audits, FMDS.

Responsible for evaluating, improving, document manufacturing methods for new and existing products (ECI) create standardize work instructions, identify troubleshoot issues and resolve that impede manufacturing.

Exercise leadership to major complex manufacturing projects bearing directly on Company objectives take ownership of process, do lean productivity studies find requirements for future manufacturing, investigate problems provide corrective action (CAPA) using SPC, FMEA and train operators based on Gauge R&R.

Strong tie to internal and external Customers, vendors to effectively drive achievement of production needs, product specifications, material and equipment and solid understanding of the Demand/Supply Chain Process.

Provide corrective actions with PDCA, root cause analysis that emphasize on continuous improvement (kaizen), practice JIT and 5S and conduct statistical process control(SPC) with ISO standards and quality policies, Quality circles, Jishuken, Hijunka, Production Kanban, supplier Kanban, poka yoke and Jidoka process.

Incorporate diverse requirements of safety, Quality, productivity and cost for manufacturability, 5S Audits.

Interface with Quality, planning to meet production schedules, production specifications and TBP problem solve by finding Root cause analysis to provide corrective and preventive action using tools like Fishbone, 5Y.

Ganesh Machinery, California - (July 2010 – Feb 2011)

Process Engineer

Ganesh Machinery is the manufacturer and seller of CNC Horizontal and Vertical Milling Machines, manual Lathes supplying to Aerospace, medical, schools, Automotive and research development which ranges from 3 to 7 Axis

Responsibilities

Exceed requirements by scheduling work, evaluating parts and labor planning and works force utilization for CNC Assembly process and routing parts in assembly environment, testing CNC by programming for accuracy.

Responsible for supervising shop floor, maintaining metrics, reorganizing and maintaining inventory.

Utilize FMS (Field Management System) an ERP system to maintain inventory and service records.

Ability to multi-task while working in a dynamic environment with frequently changing priorities and deadlines.

Strong knowledge MRP and BOM structure as well as Production Scheduling of operations in process.

Understand and be able to apply Lean 6 Sigma in order to achieve complete customer satisfaction through process improvements and identifing KPI’s to drive Quality, productivity.

Incorporate diverse requirements of safety, Quality, productivity and cost for manufacturability, 5S Audits.

Maintain activity boards of daily report and confer for production capabilities, equipment performance, track defects for non-conformance using Gauge R&R analysis, Fishbone and provide Corrective action.

Tumkur Precision Pressing Works, India – (Aug 2006 – June 2009)

Mechanical Manufacturing Engineer

Manufacturer and exporter of sheet metal components, metal forming, aluminum heat sinks, press tools Aluminum bus bars, Precision Auto Turned Parts and Components Press Tools, CNC machined parts

Responsibilities

Evaluated, improved and documented manufacturing processes and created work instructions, BOM for the routing of part in CNC 3-axis machines and implement cost savings method in improving process methods

Assisted in tooling and fixtures design using AUTOCAD for improved production efficiency based on change in customer specifications of product and requirements for change in manufacturing process ECO/ECN

Experience in maintaining up to date production documents , ISO standards, metrics and implementing KPI’s

Monitored production and troubleshooted problems of equipment by identifying root cause analysis and provided the corrective actions, meet the production schedules, capabilities to and customer demand.

Verified required materials and supplied according to production schedules and production specifications.

Participated in programs, meetings to ensure optimum and efficient use of resources and Cost estimation.

Analyzed and maintained ordering plan, standard operating procedures (SOP’s) and production schedules.

Coordinated with suppliers for right material, quantity arrives for production and final material approval (MRB).

Forecast accuracy of inventory and planning strategies to meet organization goals of on-time shipments OTD.

PROJECTS

July 2009 – May 2011

Solid Works design - Designed a shock absorber assembly and suspension of vehicle, performed stress analysis of parts, Materials used, DFM, created BOM, drawing sheet and exploded views for better analysis

Master Cam - Machined gun prototype with Solid Works design, Master CAM codes in HAAS CNC

Lean Manufacturing - EATON Aerospace, Los Angeles

* Continuous Process Improvement – Flow down from customers to contracts and manufacturing.

* Drafted current and future value stream maps and documented standard procedures, 5S, Kaizen.

Six Sigma Quality Green Belt (Six Frogs Project) - Improving the process by increasing Jump ability of frogs according to customer requirements with DMAIC, SPC, FMEA, Root Cause, Cpk, Gauge R&R

Computer Integrated Manufacturing - Designed a layout for two lines of automated food packaging

Robotics - Designed layout, Programmed Pegasus, Fanuc Robot to automate Golf Ball Packaging technology

PLC Project - Automated Vertical Indexing conveyer system for production line, fabricated hardware with electrical control board and programmed PLC using RS Logix.

EDUCATION

M.S Degree in Manufacturing Systems Engineering and Management - CSUN (GPA 3.75)

B.S Degree in Mechanical Engineering - VTU – (GPA 3.6)

CERTIFICATION / ACHIEVEMENTS

Diversity and Inclusion Training (PHASE 1&2) - Sept 2011

Six Sigma Green Belt Certification - Aug 2010

CSUN Honor’s co-op and department scholastic award - May 2011

Lean manufacturing Certified - Aug 2011

Member: Society of Manufacturing Engineers - Aug 2009 to present

John and Jo Guarrera scholarship award-Jun 2010

Vex Robotics Competition, LA Valley College: Judge - Feb 2010 &Nov 2011

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