Dynamic Engineer Seeks New Opportunity 2012
- 1. Rahul Laxman Iyer US Citizen Six Sigma Black Belt & Lean Manufacturing Specialist Master of Science in Engineering (Mechanical), December 2002 Western Michigan University, Kalamazoo MI USA [email protected] Telephone: +1-(623)-428-7032 Mobile: +1-(623)-570-2848 http://www.linkedin.com/in/rahuliyer 220 North 22nd Place Unit 1008 c/o Mrs Pham Thi Phuong 469 Hoang Huu Nam Street Mesa AZ USA 85213 Long Binh Ward, District 9 Ho Chi Minh City Vietnam
- 2. Objective & Summary Of Qualifications Looking for long term opportunity in process improvement & development. Trained in Six Sigma Black Belt & Toyota Production Systems,experience in product/machine/fixture design, and review of new trial parts. I have lead people, and resolved issues, improved productivity, increased profit, and generated new business utilizing process improvement, and problem resolution. Demonstrated history of leading process improvement, producing accurate, timely reports,meeting stringent customer expectations, and ultimately resulting in cost savings. Thrive in a deadline-driven and data-driven environment.
- 3. • US Citizen Qualifications • Master of Science in Engineering (Mechanical), Western Quality Value Michigan University (Kalamazoo MI USA), Dec 2002 Customer/Client • Project Management Satisfaction Professional (PMP) (expected Jan 2011) • Six Sigma Black Belt Service (2003) • Certified Quality Engineer (ASQ-CQE) (expected Apr 2011)
- 4. Qualifications (Continued) • Languages Spoken – English (Native Speaker) – Spanish (Proficient) Quality Value – Vietnamese (Rudimentary) – Russian (Rudimentary) – Tamil (Rudimentary) • Data Driven Customer/Client • Proven Track Record Of Satisfaction Managing & Implementing Initiatives To Improve Quality, Cost, & Delivery, And Delivering Value • Strong Background in Service Supplier Development & Warranty Reduction/Analysis
- 5. Needs Served Toyota Production System Lean Manufacturing & Six Sigma Black Belt Strong, Effective Data Analysis MSE Mechanical Engineering Strong, Effective, Process Control, Optimization, and Cost Savings Strong Technical Background Quality Assurance Data Driven Analysis & Understanding Of Technical Concerns Customer/Supplier Relations Creative, Effective, Measurable, Solutions & Results Root Cause Analysis Effective, Measurable, Creative, Countermeasures Satisfied Customers, Fewer Nonconformances, Reduction in Costs
- 6. LEAN/SIX SIGMA/KAIZEN/VA/VE PROJECTS (Cost Savings) • Jernberg Industries Inc, JII Machining Division • Lead project to redo layout of two stage CNC machining cell to improve flow & improve quality. Layout redesigned as a kaizen to address numerous quality issues at the customer in regard to parts missing operations & low yield. Savings US$200K annual Tools Utilized: Process Mapping, Time Study, Process Walk, Takt Time, COQ, FPY, CAD/CAM (AutoCAD), Measuring Probes (Siemens/Moore Data Gauges) • Dana Corporation • Lead production plant, total of 20 people in Value Stream Mapping & establishing a Rapid Baseline among lines of Dana Production Systems (DPS). Information used to develop foundation, set priorities, and coordinate lean activity for fiscal year, and to mentor and train others in lean concepts and kaizen. Total of 3 Black Belt opportunities identified, 8 kaizen opportunities identified. Tools Utilized: Pareto Analysis, Process Mapping/VSM, Financial Analysis/ROI, Kaizen, Time Study, Process Walk, Takt Time, COQ, Takt Time, FPY • Mentored, trained, and coached ISO 14000 Coordinator, and Quality Manager in Lean concepts, kaizen & 5S techniques, and Six Sigma. Quality Manager, and ISO 14000 Coordinator went on to be certified Six Sigma Green Belts through Dana Corporation. Tools Utilized: Pareto Analysis, Process Mapping, Kaizen Event, 5S, PDCA, COQ, Takt Time, Hypothesis Testing, SPC, One-Piece-Flow, Time Study, Root Cause, FMEA/EMEA, QFD/SIPOC, FPY, Cell Layout, PDCA, Financial Analysis Training • Lead Six Sigma Black Belt Project, Mentored & Trained Team of 7 people over course of 6 months (including outsourced paint supplier), Optimizing Driveshaft Painting Process. Savings US$200K annual. Tools Utilized: Pareto Analysis, Process Mapping, Financial Analysis/ROI, Hypothesis Testing/ANOVA, Kanban, PDCA, SPC, Root Cause, Fishbone, Why-Why, COQ, QFD/SIPOC, FPY, P-FMEA • Lead Six Sigma Black Belt Project, Mentored & Trained Team of 4 people over course of 6 months, Worker’s Compensation Management Process. Savings US$220K annual. Tools Utilized: Pareto Analysis, Process Mapping, SPC, Root Cause, COQ, PDCA, EMEA
- 7. LEAN/SIX SIGMA/KAIZEN/VA/VE PROJECTS (Cost Savings)--Continued • Dana Corporation • Lead Kaizen Event, Mentored & Trained Team of 5 people over one week, Driveshaft Remanufacturing, reduction of time from 9 days to 4 days to remanufacture driveshaft, true labor cost of remanufacturing driveshaft realized. Savings US$170K annual. Tools Utilized: Pareto Analysis, Process Mapping, 5S-Shadow Board, Time Study, Pokayoke, Takt Time, One-Piece-Flow, FPY, Cell Layout, Financial Analysis/Calculating ROI • Supplier Development, Lead team of 3 people with setting up kanban for tube cutoff length through kaizen. Savings US$10K annual Tools Utilized: Process Mapping, Kanban, Milk Runs, SPC, takt time • Project Manager for a new line of driveshafts that encompassed localizing five different series (in charge of tooling development, developing and maintaining project timeline, and assisting Purchasing Manager with sourcing of components). US$4.2 million in new business annually & and allowed closing of warehouse for receiving of overseas product (reduction of 3 people), savings of US$150K annually. Trained & mentored Production, Maintenance, Quality, and Sales people regarding new production equipment and driveshafts. Tools Utilized: MS Project, PERT/CPM, Pareto Analysis (80/20), D-FMEA, P-FMEA, Cell Layout, ROI
- 8. LEAN/SIX SIGMA/KAIZEN/VA/VE PROJECTS (Cost Savings)--Continued • Dana Corporation • Value Analysis & Value Engineering (VA/VE) experience with the redesign of a Spicer Axle used in golf carts (designed 42% of the cost out of the product; improved fit, form, function, capitalized on Dana Corporation patent, met target price, simplified product design, reduced from US$290 to US$170 per part. Savings of US$150K annual). Tools Utilized: Technical FAST Diagram, Component Breakdown, Function Breakdown, QFD • Haldex Hydraulics Corporation • Supplier Development, Lead supplier, total of 3 people, in process improvement in sand casting of grey iron and part machinability. New specification and expectation developed with foundry and in-house process resulting in reduction of nonconformances of 30%, reduction of 200% inspection labor of one person. Savings US$25K annual. Tools Utilized: Pareto Analysis, Cp/Cpk, ANOVA, Hypothesis Testing, Design of Experiments, Process Walk/Mapping, pokayoke, COQ, Root Cause, Why-Why, Kanban, P-FMEA, Zone Charting/SPC, FPY, Cell Layout • Supplier Development, Lead supplier of deep drawn cylindrical hydraulic reservoirs in a series of kaizen events aimed at improving layout of shop floor. Supplier had several presses and related, and the process just did not flow with current layout. Kaizen efforts lead to reduction of nonconformances by 50%. Savings of US$20K annually. Tools Utilized: Pareto Analysis, Process Walk/Mapping, pokayoke, COQ, Root Cause, Why-Why, Kanban, P-FMEA, SPC (P & NP charts), FPY, Cell Layout, 5S, Shadow Boards Aisin Manufacturing Illinois LLC • Lead efforts to resolve popping noise with powered back door unit through use of Taguchi Design of Experiments (DoE). Savings US$60K annual Tools Utilized: Pareto Analysis, Root Cause, Why-Why, FPY, Design of Experiments, Process Walk/Mapping, Cp/Cpk • Tepro Industries Incorporated • Lead Kaizen activities in area of finishing at plant, total of 4 people, assisted in-house processes in reduction 200% inspection in Finishing. Resulted in labor reduction of four people. Savings US$45K annual. Tools Utilized: Pareto Analysis, Process Walk/Mapping/VSM, Pokayoke, Root Cause, Why-Why, COQ, takt time/ratio 1, FPY • Supplier Development, Lead team of 4 people in looking at whole picture through monozukuri, covers everything from logistics, storage, and packaging. Assisted in redoing “milk runs” that cover two suppliers. This was done through kaizen. Savings of US$7K annual. Tools Utilized: Process Mapping, Process Walk, Kanban, Kaizen, Milk Runs
- 9. LEAN/SIX SIGMA/KAIZEN/VA/VE PROJECTS (Cost Savings)--Continued • Tepro Industries Incorporated • Supplier Development, Lead team of 4 people, plus 25 suppliers, in developing, training, educating, and tracking suppliers on process improvement, including Quality, Cost, and Delivery. Established system to rate, train, and develop suppliers. Savings of US$25K annually. Tools Utilized: Process Mapping/Cell Layout, Kanban, Kaizen, 5S, COQ, FMEA, Shadow Boards • Supplier Development, Low Cost Carrier (LCC) Countries, assisted in PPAP’ing, and qualifying 20+ parts moved from Tennessee to Thailand as far as production. Savings of US$15K annual. Tools Utilized: APQP/ANPQP, Pareto Analysis, AQL Level 1, COQ, FMEA • The Timken Company • 5S Introduction and Education. Increased availability in Wax Injection by 5%. Tools Utilized: Shadow Board/Toolbox, Cell Layout • Optimization of various molding and shelling techniques, and in mold shrinkage. Tools Utilized: Design of Experiments • Vantage Mobility Internationa LLC • Cost Justification for Process & Module Redesigns on Honda Van retrofit. Reduction of 1.25 labor hours per vehicle. Tools Utilized: DFMEA/PFMEA, Process Mapping, 5WhyAnalysis/Why-Why Analysis/Root Cause, Time Studies
- 10. ACADEMIC/RESEARCH PROJECTS-- – Continued Rose-Hulman Institute of Technology • Technical Commuunication/Jaipur Foot Workshop (Jaipur, India) : Wrote a Technical Report on the Jaipur Prosthetic Foot. Report documented the design, the manufacturing process, and the results and need for the Jaipur Foot. This included a visit to the Jaipur Foot Workshop in Jaipur (India), originally setup by P K Sethi MD in Jaipur, and a visit to a tire/rubber retreader in an village in India. Presentation was also made at Rose-Hulman of the research on prosthetic foot. Assisted the Jaipur Foot Workshop in improving process documentation. Tools Utilized: Excel & Graphical Analysis/Speadsheets, MS Publisher, MS Word, Graphics Design, Flow Charts/Process Maps, MS PowerPoint • Machine Design/American Buff International (Paris IL): Consulted as part of a team with small startup company (no engineers on site, worked with Production Manager). Company manufactured rotary abrasive cutting/polishing/finishing wheels. Redesigned rotary assembly equipment to allow company to manufacture production more efficiently. Assisted in optimizing specifications of product, and determining process controls. Simplified assembly process. Savings of US$20K annually. Tools Utilized: Process Mapping/Standardized Work (Jidoka), Kaizen, PDCA, COQ, Takt Time, Time Study, Cell Layout, Financial Analysis/ROI, Machine Design (CAD/CAM—AutoCAD/Pro Engineer), Design of Experiments (DoE)/Optimization, Excel & Graphical Analysis/Speadsheets, , Flow Charts/Process Maps, MS PowerPoint
- 11. ACADEMIC/RESEARCH PROJECTS-- Continued – Rose-Hulman Institute of Technology • Medical Prosthetic Design/Rose-Hulman Ventures (Terre Haute, IN): Assisted in design and development of an artificial larynx made of silicone rubber. Tools Utilized: Materials Analysis, CAD/CAM (AutoCAD/Pro Engineer), Financial Analysis/ROI, QFD, FDA cGMP & 501K/PMA, MS Excel/Word/PowerPoint • Facility Layout/Specialty Plastics Inc (Shelburn IN): Redevelopment and moving of production to new facility. Production layout of equipment in new facility. Savings of US$100K annually Tools Utilized: Financial Analysis/ROI/Payback, Production Cell Layout, Building Requirements, Local regulations & standards for production facility, Development of utilities to service new facility, Logistics, MS Excel/Word/PowerPoint – Western Michigan University • Advanced Design/Stryker Instruments (Kalamazoo MI): Redesign of trauma reamer for a 3:1 torque ratio, rather then a lower torque ratio Tools Utilized: CAD/CAM (AutoCAD/Pro Engineer), QFD, Component Breakdown/Functional Breakdown, Gear Design/Analysis, Pugh/TRIZ, MS Project, DFMEA
- 12. ACADEMIC/RESEARCH PROJECTS-- Continued – Western Michigan University • Project Management/Spring Technologies Corporation/Petersen North America (Portage MI): Implementation of Lean in an assembly operation. Savings of US$170K annually Tools Utilized: Pareto Analysis, Process Walk/Mapping, pokayoke, COQ, Cell Layouts, Kanban, P- FMEA, FPY, 5S, Shadow Boards, Project Management, MS Project, PERT/CPM, Machine Design, Work Instruction, Pareto Analysis (80/20), Kaizen/Standard Work (Jidoka) • Two Phase Particle Fluid Flow In Couette With Non- Spheroidal Particles: Experimental verification of a theoretical CFD model. CFD model proposed earlier by M Yoda PhD (Georgia Tech) & D Qi PhD (Western Michigan University). Tools Utilized: Machine Design, Flow Visualization/Cameras, CFD/Fluent/Fortran
- 13. My Strengths Re Cu Maste s du ce Rel tomer Degre r’ s dC atio e os ns s is s to d A n at a r ts Cu tisfie me t aly Improveme n D Pro cess Sa Sales More Customer Technical Quality Ma xpe Ma Service Skill i on r na rtiis s R e ppl ie na t s E E ge e Sa ge e l es M o lat e me d me Su ce anc & I re Creative du m n nt nt Re nfor Pr cre ive ofi as & Effect co t ed Solution s N on
- 14. Key Benefits • Improved Customer Relations • Improved Supplier Relations • Improved Quality • Improved Delivery • Reduced Costs • Increased Sales/Profit • Increased Value
- 15. Next Steps • CONTACT ME!! • I am actively looking for new opportunities in the following geographic locations: • Metropolitan Phoenix AZ USA – Phoenix, Mesa, Scottsdale, Tempe, Chandler, Gilbert, Glendale, Peoria, and other locations in metro Phoenix • Metropolitan Ho Chi Minh City Vietnam – District 9/Thu Duc, Binh Duong, Dong Nai/Bien Hoa, Cu Chi, Saigon/Ho Chi Minh, Tay Ninh, Vung Tau/Ba Ria, Long An