Manufacturing/Industrial Engineer with 2+ years of experience with Manufacturing & Pharmaceutical industry. Have knowledge and experience of rapid prototyping, designing manufacturing process, documenting the Production Part Approval Process (PPAP), Process Failure Mode Effects Analysis (PFMEA) and control plans for manufacturing equipment.
Experience of designing products and manufacturing assembly line using ProE Creo/AutoCAD
Experience in executing cleanroom validation & qualification protocols (IQ, OQ, PQ) according to cGMP and FDA regulations (21 CFR).
Working Knowledge of problem-solving techniques including 8D, root cause analysis, and 5 Whys. Also, experience in handling CAPA reports.
Skilled in conducting Statistical Process Control (SPC) for critical parts.
Hands-on experience with lean manufacturing tools such as- 5S, Kaizen, PDCA, and TQM.
Working knowledge of 7 Quality Tools- Ishikawa, Check Sheet, Control and Pareto Charts, Histogram, Scatter Diagram, Flowcharts.
Internship at FireEye, Inc. exposed me to different aspects of Program Management: Managing SKU configuration, manufacturing quality, Hardware testing, the Setup process for EOL, process improvement, data analysis for generating metrics every week. Overall, the training gave me a basic understanding of Program management.
Certification: Six Sigma Green Belt & AutoCAD.
In addition to undergraduate courses and projects in Bachelors in Mechanical Engineering at Gujarat technological University, the graduate courses of Masters in Industrial Engineering at San Jose State University undertaken by me including - Manufacturing Engineering I & II, Operations Planning and Control, Supply Chain Management, Lean Six Sigma have expanded my horizon in Operations and Supply chain/Logistics domain.
Experience with SAP ERP, Python, R Language, SPSS.
If you believe that my experience and skills can add value to your organization, I would be happy to connect with you and discuss potential opportunities.
I can be reached on alaymahadkar@outlook.com
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Experience
Manufacturing Engineer, Intern @ FireEye, Inc. - Jun 2019 – Aug 2019
Solved product/process and failure challenges in Network security hardware. Performed process characterization to create better
performing product. Analyzed & improved the manufacturing and assembly process of products by using Six Sigma methodologies.
• Created a data visualization dashboard generating KPIs for monitoring issues in production, quality, and logistics using Python.
• Performed Root Cause Analysis (RCA) based on KPIs of error codes and directed quality incidents investigation on HW tests.
• Automated PCB rework process through integration of final test and assembly systems leading to 19% rework stock reduction.
• Implemented 5S and Kaizen on factory floor to optimize RMA process cycle-time by 20%.
• Validated and tested equipment by coordinating with suppliers on design and process capability for various products.
• Designed product on 3D CAD Creo software for material reduction to cut costs by 12% using Design for Manufacturing (DFM).
• Published & managed BOMs, ECO, SOP & Non-Conformity Report (NCR) for main floor assemblies using Agile & JIRA.
Industrial Engineer @ Wockhardt Pharmaceutical Ltd. - Sep 2016 – Dec 2017
Performed Root Cause Analysis (RCA) to solve complex engineering problems. Worked with various teams and performed EVT/PVT
to setup a drug manufacturing facility. Established Quality Management System (QMS) to increase production and yield.
• Managed supplier quality, system design, testing & verification, and FAT/SAT teams for 12 compressor house installations.
• Developed FMEA reports for electromechanical systems by identifying MTBF & failure mode to reduce breakdown by 15%.
• Utilized statistical tools (such as GR&R, SPC and Cp/Cpk) and drove Time & Motion Study (MOST) to improve OEE by 7%.
• Performed Design of Experiments (DOE) & generated data analysis reports using JMP and Excel to improve reliability.
• Developed capacity planning models using linear programming & SAP ERP system for maximum capacity utilization.
• Forecasted demand for rolling 6 Quarters by analyzing historical data and sales projections to reduce overstocking by 18%.
• Executed process validation & qualification protocols (IQ, OQ, PQ) according to cGMP (FDA:21 CFR) for new product launch.
• Performed First Article Inspection (FAI) during NPI to reduce manufacturing delays and the overall cost of the product.
• Led a cross functional team to pilot NPI that set up a model to save labor & inventory cost up to $120k per batch.
• Developed Request for Quotation/Proposal (RFQ/RFP) and Product Part Approval Process (PPAP).
Production Engineer, Intern @ Pioneer Extruders Pvt. Ltd - Jun 2016 – Sep 2016
Designed plant floor schematics including layouts and production sequences to save space using AutoCAD. Collected Manufacturing
Execution System (MES) data using SQL and analyzed it to optimize a fast-paced manufacturing line by increasing Takt-time.
• Resolved quality issues by publishing 5+ Failure Analysis reports and applied Corrective & Preventive Actions (CAPA).
• Supervised Reverse Logistics and analyzed data to troubleshoot weak links with customer service and provide SLA turn times.
• Designed & installed material handling conveyors to reduce transfer time by 20% with Capex $80k and achieve SMED target.
• Implemented lean manufacturing methodologies to improve the Operational Uptime by 5% & reduced Queue time by 50%.
• Improved production efficiency from 105K to 135K tubes/day by implementing line balancing for optimized material flow.
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Projects
Development of Production Plan (Tools used: DMAIC & DMADV, MPS, MRP, Kanban, Minitab, ProModel)
• Forecasted demand & costs using mathematical models; performed capacity planning & supply planning for on-time delivery.
• Implemented Kanban material management system to optimize warehouse operations & reduce $20000/year inventory cost.
Analysis of vertically integrated supply chain (Tools used: EOQ, Capacity distribution, last-mile delivery)
• Resolved stock out issues by redesigning product supply plans through continuous data analysis & safety stock levels.
• Designed distribution network with last mile delivery to reduce logistics cost, response time and increase productivity.
Manufacturing prototype of gas turbine combustion chamber (Tools used: DFM, DFA, FEA, MTBF, ANSYS)
• Designed & manufactured gas turbine combustion chamber using Pro-E/Creo and machining tools (lathe, drills, welding).
• Conducted finite element analysis (FEA) in ANSYS for fault tolerancing, thermal stress, reliability and failure thresholds.