Georgetown, Kentucky, United States
Experienced Engineer with a demonstrated history of working in the mechanical or industrial engineering industry. Skilled in DMAIC, Microsoft Word, Six Sigma, Lean Manufacturing, and Continuous Improvement. Strong engineering professional with a Master of Science (MS) focused in Manufacturing Engineering from Kettering University.
• Lead TMNA Unit SR project planning and investment activities by working with multiple TMNA, NAMC, & TMC departments • Support cost planning milestones activities by leading in house cost estimation studies • Lead project VE activities for in house cost reduction activities and target cost achieving • Lead Nemawashi activities, project approvals, and issue Basic plan • Support TMNA HQ for unit formation type studies to set overall unit strategy • Support NAMCs, E&F, & PE in creating Ringi explanation by reviewing scope, benchmarking, investment, schedule, and tech assist. • Support TMNA Annual Plan (AP) activities by analyzing PEM data and raising concerns through PFS • Lead model change studies for in house parts to provide study result analysis for TMC lead model changes • Support Make vs Buy by leading in house cost study for new business opportunities • Lead planning of multiple projects, maintain good communications with TMNA PE management for updates on projects via weekly report and Ringi tracking matrix.
• Develop investment estimates based on capacity and production mix required. • Create project schedule in alignment with TMNA PE Master OP. • Plan & lead VE activities to reduce cost and increase productivity. • Prepare the core planning outputs for the Gear machining lines • Lead machine selection and machine specification activities with customer first mindset. • Communicate with trading companies & machine makers to streamline procurement, approval, manufacturing, and validation of machines. • Support creation & validation of line layout and installation drawings for contractor selection and installation. • Direct commissioning activities of new and modified machines and robots. • Manage problem solving and countermeasure activities for gap items by working with Seibi, SVs, MC Makers, Contractors, & Plant side. • Lead pre-production trials and launch safe & qualified gear machining lines • Improve performance of production cells using monitoring tools like Power BI.
• Slashed tooling costs by $5 million per year by inventing and implementing tool life calculation model. Trained multiple engineers from the USA, Canada, & Mexico to yield higher cost reduction for other plants. • Identified, analyzed, and developed tooling suppliers to provide top quality tooling for GMPT, Toledo which reduced pre-pulls from 20% to 7%, machine downtime, & tool cost. • Pioneered tool family based standardized projects which dramatically improved part quality and aggressively reduced tooling cost. • Achieved topmost results by leading team of tool engineers to create measurement programs for new pre-set machines which will greatly increase tool pre-set quality. • Developed & executed a probability-based model by applying lean manufacturing and six sigma theories to optimize POU inventory to reduce cost by $ 500,000.
• Resolved plant’s top scrap issue o Aligned with GM engineering to solve complex scrap associated issues. Optimized tap drill and tap geometry to control minor diameter and truncation. o 162 Failures in 2015 (~$ 120,000 scrap cost), 83 failures in 2016 till October (~$ 60,000 scrap cost) reduced to 0 failures since November 2016. • Cost Savings achievements (Prismatics) o 9.46% yearly tooling cost reduction (6 & 8 Speed RWD) in 2016 o 14.11% yearly cost reduction (6 speed RWD) in 2017 o 53.13% yearly cost reduction (8 speed RWD) in 2017 • Quality driven Improvements: O Optimized RWD valve bore tooling to resolve sub-assembly rejects.
Data mining for drilling depth estimation in oil exploration o Compiled the data and conducted tests through various data mining techniques. o Formulated a model with 6 rules to obtain 80% accuracy.