Hello, I am Juned, an enthusiastic, results-driven professional with Master’s in Mechanical Engineering and 3+ years of experience in Mechanical Design, Manufacturing, Quality and Project Management
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Experience
Daimler Trucks North America – Continuous Improvement Projects Intern
• Boosted workplace efficiency and effectiveness by assisting with key improvement projects to identify issues, driving troubleshooting and process problem solving until resolution, and procuring new die and fixtures.
• Reduced total routing across plant 5%, saved $30K in production cost, and maximized production of automotive parts by defining rate, and adjusting overall routing by 1267 hours.
• Reduced material handling and operator wait time 7% by determining optimum size of bins per part variant.
• Decreased scrap 8% for time studies on 250-part variants by establishing optimal number of coils required.
Mercedes-Benz Vans – Manufacturing Engineering Intern (Body-in-White and Assembly)
• Reduced rework rate and defects 20% per van by conducting root cause analysis to identify misaligned punching guide holes.
• Optimized manufacturing capability by developing and implementing standard work instructions, process steps, and training documentation.
• Strengthened manufacturing processes by creating and maintaining PFMEA and process flow charts and devising and executing process audit to incorporate new fixtures, jigs, visual signals and revised work practices.
• Established standard time required for each station on production line by initiating Machine-Time Measurement (MTM) and cycle time analysis study.
Toyo Engineering Limited- Mechanical Design Engineer
• Enhanced vendor compliance by establishing timelines to monitor progress, measuring performance, and ensuring contract terms adhered to.
• Heightened client satisfaction by providing technical support, and swiftly resolving technical queries in absence of senior project leaders.
• Generated $5K in cost savings, improved turbine efficiency 5%, and reduced vibration to 2.9 mm/s from 9.0 mm/s by initiating root-cause analysis and DFMEA to identify steam-induced vibration within turbine and adjusting lube oil pressure and temperature.
• Raised efficiency and productivity by designing equipment, writing documents on product dimensions, project targets, supplier’s product quotations and vendor data sheets, and creating site installation reports in cooperation with multi-disciplined engineering teams.
• Enriched engineering teams’ knowledge on modeling and drafting techniques by educating and guiding team on tolerance analysis and component merging concepts in Solid Works and ANSYS.
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Projects
1) Reliability Analysis of Vehicle for Side Impact Protection during Crash
Determined potential of human injury during car crash by measuring the abdomen load, rib deflections, viscous criterion, and pubic symphysis force. Reduced test failure rate by fine-tuning reliability analysis equations using the FORM method in MATLAB.
2) Simulated Airplane Manufacturing Factory Design
Designed a simulated factory with a production capacity of 25 airplanes/day by developing an 18-step airplane building process to be divided among 4 operators. Optimized factory design layout by using 5S, poka-yoke, and Kanban and Kaizen principles; identified and resolved labour inefficiencies by applying COMMWIP, value-stream mapping, and theory of constraints.
3) Development of 3D Prototype of Platform Jack using Additive Manufacturing
Improved prototype compatibility with 3D Poly Jet MJP 3600 printer by designing a scaled-down version of a platform jack using Siemens UG NX. Determined that the 3D additive manufacturing method was a more accurate design, production, and assembly method for complex-structured objects compared to the component-based conventional manufacturing method. Reduced build-time from 17.5 hours to only 7.5 hours by reducing the number of meshes while maintaining durability in MeshLab.
4) Design of Experiments (DoE) to Optimize Parameters Affecting Combustion
Examined key nuisance and response variable parameters affecting combustion, such as exhaust retarder, camshaft overlap, camera angle, and residual mass by performing analysis on a 2L Ford gasoline engine at various speeds between 2000 rpm to 3000 rpm. Reduced number of combustion tests by 48% by developing factorial models to adjust parameters using Minitab. Improved result accuracy by employing hypothesis, Tuckey’s, and chi-square testing methods; used R to perform ANOVA.
5) Smart Stove Project
Developed a fuel-efficient stove from product conceptualization through testing and validation in collaboration with a 4-member team. Project was published in the International Journal of Research in Engineering & Advanced Technology.