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Lean Systems Coordinator/Manufacturing Engineer

Location:
Sumter, SC, 29150
Salary:
65000
Posted:
September 21, 2008

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Resume:

VIJAY KUMAR RAMASUBRAMANIAN

Home –*** Pocataligo Dr., Sumter, SC-29150, Phone – 803-***-****

Home Email- *******@*****.***, Office Email- *****.***************@************.***

OBJECTIVE: To find a position where I can utilize and enhance my skills in Lean manufacturing and Six Sigma and work diligently in continuous improvement of processes and systems towards the pursuit of perfection

SUMMARY: Excellent team player and enthusiastic Leader who has been aggressively leading teams towards continuous improvement in manufacturing for 3 years.

EDUCATION:

University of Kentucky, Lexington Masters in Manufacturing Systems Engineering GPA: 3.9/4.0, Graduated – June 2006

Lean Six Sigma Training -Lean Systems Certificate – UK Lean Boot Camp Summer 2005

University of Madras, India, Bachelor of Engineering – Production Engineering, Graduated - June 04 - GPA - 3.4/4.0

WORK EXPERIENCE:

Federal-Mogul Corporation, Summerton, SC – From July 06- Current - Lean Systems Co-ordinator/Manufacturing Engineer – Tier 1 Automotive Parts supplier

Roles and Responsibilties

Champion the process of ongoing continuous improvement of processes and systems

Lead Kaizen Events and track progress of Kaizen implementation using Value Stream Mapping and A3 tool.

Train, Coach and facilitate team members of various levels of the organization to practice the lean tools

Establish and manage Lean systems to control and reduce Finished goods, WIP and purchased parts inventory

Team Leader for Plant Layout improvement, to achieve Lean Flow Ideals

Achievements and Major Projects

Using tools like Standardized Work, Operator Balance Charting (Yamazumi), achieved single piece flow and takt with optimal manning, safe and ergonomically designed work for different processes. Such Kaizens yielded annual productivity savings of over US$ 0.57 million.

Trained people on SMED principles and reduced changeover time in processes like Stamping press, molding machines, and assembly machines. Established Setup Management systems.

Implemented 6 S and Visual Management systems in a model cell and assist Operations Managers in horizontal deployment of the same throughout the plant.

Implemented Level Loading, Supplier Kanban, FIFO and WIP Kanban over several Value Streams and achieved 100% Delivery, reduced lead time, OT and parts shortages.

Used FM problem solving process for customer related quality issues and solved problems by setting up standardized work processes, 100% source inspection, one piece flow and training operators on the internal customer model.

Setup and manage Water Spider routes and adherence tracking systems thereby reducing material handling and WIP.

Lead a Plant information Systems Project to reduce Inventory Errors

Responsible for creating a safe, ergonomic workplace and contribute to the team by conducting regular STOP and safety tours to achieve 1 million hours without an accident in the plant.

Lead the Maintenance team on implementing Lean Maintenance program

Federal-Mogul Corp, India (May 07 – Sep 07) – Manager, Projects – Sealing Systems India – Interim Opportunity

Part of the Global Manufacturing Engineering Team to initiate setting up of a new manufacturing facility in Bangalore, India.

Worked on a cross functional team to create Project Implementation Plan.

Created Plant Layout and ensured Layout met Flow and Safety Ideals.

Identified and assessed Local potential Machinery suppliers for Manufacturing Equipment and plant utilities equipment.

Acted as a Liaison between the Global Manufacturing Engineering Group and Architect contractors in the plant design

SPX Filtran, Lugoff, SC, Lean Manufacturing Engineer Intern (March 06– June 06)

Lead Current State and Future State VSM events

Created and Improved Standardized Work.

Generated PFEP and setup a Supplier Kanban system for purchased parts

Implemented POU Storage for components thereby reduced inventory in warehouse and eliminated staging.

TVS Brake Linings, Chennai, India, Manufacturing Engineering Apprentice – Jan 04 – July 04

Learned and used the 7 QC tools in TQM and reduced scrap in drum brake lining manufacturing from 3 % to 2 %.

Conducted Time, motion studies and line balancing in a single operator multi-station type brake linings finishing cell

ACADEMIC - INDUSTRY PROJECTS:

Semicon Associates Lexington, KY– Lean Manufacturing Masters Project - August 05 – January 06

Identified Product families using Production Flow Analysis

Rev-a-Shelf and Jones Plastic, Louisville, KY, June 2005

Extended Enterprise VSM Project

Trane Co., Lexington, KY –Project Student - Jan 05 – April 05

Designed a flexible welding fixture and designed cell layout to conform to Lean flow ideals.

University of Kentucky – Lean Manufacturing Boot camp 2005

Learned Lean tools using Team simulations.

Learnt the Six Sigma tools DMAIC process using simulations.

Learnt Lean tools through Plant tours to Toyota, Trim Masters, CLA, Ford & Tower Automotive

Extra-curricular activities:

Rotary Club of Anna Nagar, Chennai, India

Organized immunization camps to administer polio vaccine to underprivileged and destitute children in the city of Chennai.

Softwares: Microsoft Excel, Powerpoint, Auto Cad, ProModel



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