Experience Snap Shot Presentation (Design 3)
- 1. Experience Snap Shot Rajat Debgupta Industrial & Manufacturing Engineering University of Windsor Employment Scope: Industrial-Manufacturing Engineering Years in Industry: 1995 - Current
- 2. Management Skills and Techniques Task Identification, Delegation and Follow-up Team Player and Lead by Example Good Communication Skills Exceed Expectations set by Company and Upper Management Awareness of Cross Functional Role and Work Boundaries Problem Resolution and Action Planning Time Management and Task Objectives Executive Level Presentations Company Deliverable Matrices and Score Card Reporting Customer Relation and Requirement Assessments Interaction and Task Focus with Development and Sales Group People Skills and Management Techniques Offer Help and Support for Members at Crunch Situations Prepare Cost Structure & Resource Rendering for Approval Maintenance Management and Support Process/Manufacturing Engineering Management & Support Personal Attribute: Driven, Approachable, Team Player, Good Communicator, Trustworthy, Disciplined, Dedicated, Transparent and Task Oriented
- 3. Facilities & New Equipment Management Purchase & quote equipment, and run off new equipment for production systems Facilities layouts for manufacturing structure, materials and equipment placements Develop supplier base and support system for all tooling and equipment Recommended PM plan and spare parts management Equipment spec-out to quality, delivery, safety & environmental guidelines Database management system for critical equipment pertaining to product and build data and traceability Test equipment and calibration standards and procedures Develop CAPX proposals for Equipment Purchase
- 4. Launch & Program Management Cross Functional Team Management New Business Launch (Total Minivan Trim Div Assembly, Torque Converters, Headrests, Armrests, Seats, Lumbars, Instrument Panels, Door Panels, Front End Modules, Cut & Sew Trim Covers) Cost and Resource Structuring – Labour and Equipment Quoting Cost Estimation for New Program Launches Facilities Planning & Procurement Capital Equipment Planning & Procurement Cost Reduction Proposals and Implementation Continuous Improvement Action Planning and Implementation Strategies Customer Interaction and Follow up Overseas Launch Reporting - Scorecard and Matrices Presentation of Launch Status and Progress to Executive Board Members Problem Solving and Team Interface with Sales and Development Groups Development, PM Development, PPAP Deliverables, Budgeting, Supply Chain & Logistics Analysis and JIT Delivery Planning etc. Interaction with Suppliers (equipment and parts) Dealings with all Level of Management Exhibited Great Practitioner and Delegation Skills
- 5. Documentation Management Standard Work Instructions and Procedures - QS procedure, ISO procedure Process Flow Diagram PFMEA development PPAP documents coordination APQP/AQP management MOS (monthly operating system) report out Conversant with Six Sigma Documents (Charter, MSA/Gage R&R, Pareto Charts, Histograms, C&E matrix, Fishbone Diagram, Hypothesis Testing, Control Charts etc) Equipment matrix and Cost analysis matrix for CAPX Process Change Control and Revision change log owner Core team member for Control Plan development Supplier log and contacts New Equipment quotation matrix for project budgeting Maintenance training matrix development Problem Resolution Action Planning Program Timeline and Time & Task Management Company Mile Stones and PMS Deliverables Launch Score Card and Current Status Reporting Cost Allocations and Structuring in support of Launch Ramp Up
- 6. Product Development/Launch – Process Planning & Tooling Allocation Faurecia IS 2006 Sebring & Avenger Instrument Panels, 2007 Cadillac CTS Door Panel Injection Mold Equipment, Vibration Welder, Sonic Welder, IMG Vac Form, ABB & Reis Articulating Robot, Punch Press, Tunnel Oven, Assembly Fixturing, Error Proofing, Glue Booth, Laser Score Machine, Base Panel Assembly Line JV Lear 2005 Mustang Seat, 2005 GMX Seat, 2006 Mazda Seat, 2006 Explorer Seat Launch & APQP: Conveyor Line, Shipping System, Build Pallets, Process Fixtures, Error Proofing, Torque Tools, Infra Red Oven, Process Flow, DFMEA/PFMEA RPN Analysis, Design for Optimum Assembly DaimlerChrysler 2000 Town & Country Minivan Launch & Process Planning: Conveyor Line, Build Carrier, Robotic Urethane Applicator Cell, End Effectors, Motor Mount Fixturing, Torque Tools, IP Line, Error Proofing, In-Synchronous Parts Delivery Logistics, Ergonomics
- 7. Major Project Undertaking - 1 Gerber Cutter Uptime Study (3 Cutters) – Delay Study and Motion Study – 20% increase in uptime performance – GM (1995) Windsor Bond Robotic Cell Optimization – Time Study and Motion Study – 2 Operator Elimination – GM (1996) Implementation of Maintenance PM Program – Web Interactive PM Planner – QS Certification – Schukra of North America (1997) Work Station Design and Process Improvement (175 work stations) – Yamazumi, Time Study and Ergonomic Assessments – 15% Man Power Reduction each year – DCX (1998-2001) 2 Seating Assembly Line Modifications using Lean Techniques (54 work stations) – 5S, Time Study, AutoCAD Layout, Poke Yoke Intro – Man Power Reduction 8 heads per shift - Bing (2002) Reduction of Scrap – Six Sigma – 40% Floor Space Savings and $240K less inventory on Hand – Bing (2003)
- 8. Major Project Undertaking - 2 Reduction in Conveyor Downtime & Developed Controls SOP for Users – Lean & Six Sigma Principles – 1 shift Elimination (3 shift to 2 Ten Hour Shifts – Effective Manpower Savings 27 heads) – Bing (2003/2004) Developed all Work Station Standards for 2 new Launches (110 work stations) – MOST Study, AutoCAD – Lean Launch – Bing (2004) Launched New Facility from a MFG, Logistical, Maintenance & Administrative stand point – Equipment Procurement, Supplier Contracts, AutoCAD, Personnel Hiring, Specifications Development - Plant Operational in 3 Months, 1 st Launch in 6 Months, Lear’s Largest Operative Plant in 1 year – Bing (2004/2005) Developed Process Flow and Labour Standards for entire launch of JSC/JSD & GMX commodities – Faurecia (2006/2007) Supplier Assessment and Selection Criteria Planning and Negotiations for Outsourcing Operations – Savings of $0.09/door panel on labour + Handling & Testing Cost Savings– Faurecia (2006/2007) Developed labour standards and equipment standards to submit quote to customer for new business of Plant operating costs – Schukra (2008)
- 9. Shop Floor & Process Flow Improvements Development of AutoCAD Layouts for Space Optimization and Time Studies and MOST Analysis for Process Flow Improvements Packaging Improvements for Added Flexibility Cardboard Elimination and Re-Cycling Implementations JIT Delivery Planning and Implementation Equipment Placement and Optimizations Value Stream Mapping for Optimized Material Movements Work Station Design for ‘Parts Presentation’ and VA Work content with Ergonomic Risk Factor Assessments Yamazumi & PDCA Recording to Balance Work Content and optimization Error Proofing (Poke Yoke) and Test Equipment Planning to achieve FTY in a 1 piece flow asynchronous assembly system
- 10. Process Improvements Techniques Motion & Delay Time Studies and MOST Layout Optimization (AutoCAD) PFMEA RPN score reduction In-Process Error Proofing Methodologies Minimal Operator Dependency for Critical Operations VA/VE Strategic Process Planning (design concept) Machine Uptime and Repeatability Analysis Improved Method and Line Balancing – 1 Piece Flow/Synchronous Assembly/Modular Assembly Human Factor and Ergonomics Value Stream Mapping and Overall Flow Yamazumi & Moving Line Simulation Six Sigma & Lean Manufacturing Concepts
- 11. Training & Certifications ISO 14001 Internal Auditor Certified TS 16949:2002 Internal Auditor Certified Direct Labor Methods Engineering Certified Six Sigma Green Belt Certified MOST – Engineering Work Standard Certified Hazmat US MDOT Certified Continuous Improvement, Lean Manufacturing Training Work Shop QS 9000, TS 16949 Principles & Guidelines Awareness Trained Work Place Health & safety, Environmental & Ergonomics Training Work Shop Torque Fastening Application & Controls Trained Product Critical Component Database Management Trained Toyota & Honda Operating Principles Training Work Shop Faurecia Excellence System Principles Training Leadership and Management Training and Certified
- 12. Accomplishment Highlights 15% Labor Reduction per year = $12M Cost Save to Company (DCX) Eliminate Non-Standard contents = $1M Cost Save to Plant (DCX) Lead Process Engineer for RS Town & Country Launch (DCX) Through process improvements and lean implementations, eliminated 1 shift = 27 heads (JV Lear) Identified & Facilitized (Contractor & Supplier Interface) a Warehouse Space to a Production Facility (JV Lear) Lead Engineer for S197 Mustang Seats & J56 Mazda Seats Assembly Launch Productivity Improvements from Launch Ramp Up = $1M Cost Save to Company (JV Lear) Managed Brand New Maintenance Department with Unionized Skill Trade Workers (JV Lear) Lead Cross Functional Team for Plant Launch of JSC/JSD 27 & 41 Chrysler/Dodge IP’s and GMX 322 Cadillac CTS DP’s Launch (Faurecia) Chairperson for Plant ISO 14001 Procedure Implementation and Obtainment of Certifications (JV Lear) Monthly Scorecard and Reports Development to Corporate Head Quarters (Faurecia & JV Lear) Cost Reductions through VA/VE Task Initiatives & Process Improvements (Faurecia) Resource & Cost Restructuring Panel (JV Lear & Faurecia) Formulated Material Handling scheduling system based on customer orders per master schedule (Schukra) Created Ergonomic scoring system for all work stations for production planning (Schukra)
- 13. Personal Attributes Self Starter, Dependable, Reliable Trustworthy and Approachable Good Communicator Self Driven and can Work Well without Supervision Team Leading Experience with Good Track Record Good Time Management Skills Good People Skills Perfectionist and Detail Orientated Data and Facts Driven Can bring out the best out of team members Strong Mathematical and Analytical Skills Thrive to Exceed Goals and Expectations Good Organizational Skills – Computer Possess Good and Quick Judgment Skills Work Well with Others – Good Team Player