Torrance, California, United States
I worked for one of the leading firms in the original equipment manufacturing industry for a period of 7 years and 4 months, during which I held different positions. Initially, I worked as a Fabrication Supervisor, where I handled plant activities such as production planning, work-in-progress follow-up, and movement of raw materials from stores to the shop floor. Additionally, I was responsible for daily safety and 5S methodology undertakings. I conducted time studies in various processes such as material movement, man management, welding, and assembly. Later on, I took on the role of an ERP/BOM Engineer. In this position, my responsibilities included extracting raw data from component drawings and bills of materials using AutoCAD and calculating the cost, inputting it into Oracle-based ERP modules. I created the entire tree view by creating part masters, coding, implementing logic (using Microsoft Excel), running BOMs, generating material reports, checking BOM errors, and updating costs. I also assisted the tender departments and the Head Office in updating costs and calculating the total cost of production, including labor, material costs, and production time. Furthermore, I also worked as a Production Engineer where I managed a team of 30 members in the CNC press shop/shop floor. My main responsibilities included operating six machines, providing production support, and ensuring safety, CNC programming, reporting near-miss incidents, labor productivity, welding, fabrication, mass production of fasteners, laser components, assembly line support, and cladding. I was responsible for machine layouts and maintenance (autonomous and planned) and providing training to team members. I updated finished components and followed up on intermediate components and stock level checks using Oracle ERP. I also logged finished quantity in the ERP to inform the planning department for the smooth flow of production. I carried out internal auditing using ISO standards (ISO 2015), meticulously checking different departments for standard operating procedures, non-conformities, raising non-conformities, validation process, value stream mapping, continuous follow-up with HOD, and being a good team leader and team player. I maintained timely communication with internal and external customers and conducted 5S audits and documentation processes.
Led a 30 member team in Cnc press shop as a Production engineer in processing(cnc, fabrication) sheet metal components. Accelerated and accomplished process improvements for CNC machining operations; cut down material waste by 25% and escalated throughput by 30%. Administered and operated six heavy machineries such as CNC turret punch, Press brakes, Power press and shearing. Produced metal components ranging in grade and thickness from SS, MS(CRCA,HRPO), .8mm to 10mm. Supervised the plant and it's related activities such as 5s methodologies, TPM, Labor productivity, near miss incidents, Plant maintenance. Followed schedules from Production planning department to prepare routine production activities. Calculated Lead time and non value addition times to reduce cycle time and enhanced production efficiency to 80%. Fabricated complex metal structures, welding in flat, horizontal, vertical, and overhead positions, adhering to safety regulations and completing 200+ projects within tight deadlines, with zero safety incidents. Orchestrated the optimization of daily production phases by conducting an analysis of bottlenecks and re-engineering the process; depleted production time by 20% and escalated efficiency by 30%. Offered troubleshooting via voice and text chat, maintaining resolution rates of 80%. Standardized engineering processes by creating an SOP manual that rocketed team productivity by 25% and reduced production time by 20%. Collaborated with cross-functional teams to forecast demand and maintain optimal stock levels, reducing back orders by 80% and improving customer satisfaction by 40%. Achieved and executed a lean six sigma project that revamped production line flow; diminished production cycle time by 35% and soared monthly output by 20%. Advanced the manufacturing process by analyzing machine data and identifying inefficiencies, enabling the engineering team to reduce production time by 25% and saving INR100k in labor costs.
Developed and maintained accurate BOMs for multiple product lines, resulting in a 40% reduction in BOM errors. Created and updated BOM documentation, including BOM structures, assembly drawings, and part numbers, resulting in a 50% reduction in BOM documentation errors. Managed BOM changes throughout the product lifecycle, resulting in a 25% reduction in change implementation time. Conducted cost analysis on BOMs to identify cost optimization opportunities, resulting in a 20% reduction in material costs. Ensured accurate integration of BOMs with the company's ERP system, resulting in a 20% increase in production efficiency.