Dhruv — Reduced manufacturing lead

JAN 2018 to Present Sakthi Automotive Group USA - Detroit, MI Responsibilities: Conduct Melter, Degassing, Counter Pressure Casting Machine and Heat Treatment processes to produce knuckles with guidelines and instructions to ensure safe, efficient operation. Create Process Flow diagrams (PFD) for Planning, Organizing and managing the overall activities from Melter to Heat Treatment. Troubleshoot production equipment, processes, and materials. Good Knowledge on Industrial Automation (Fanuc Robot). Floor Layout modification to reduce direct labor and try to run a single piece process by Trimming and Sawcut machines relocation to work in cells. Reduced manufacturing lead time from 3 days average to 1-day average by implementing Cell manufacturing. Prepared current state value stream map identified bottleneck stations, and non-value-added actions resulting in whole process enhancement. Core member of the cross functional team for compiling PPAP package, developing APQP, PFEMA, Control Plans, MSA for new/current programs and documentation experience with different audits like BIQS (GM), Q1 (FORD) & VDA (VW). Updating PFEMA, Process Flow and Control plans to new AIAG standards. Assist with compliance with ISO/TS 16949 including conducting internal audits, preparing for surveillance audits, ensuring compliance with day to day requirements of the Standard. Address customer complaints (PRR's) by initiating action plans. Implementing interim containment actions and permanent preventive actions by applying 8D, fishbone and 5 why techniques. Prepare I-Charts, Pareto Charts and Trend Charts to analyze nonconformance, scrap/rejection and develop plans for corrective actions. Work closely with the Director of manufacturing on estimating the cost of poor quality and conducted Layered Process Audits (LPA) to continuously improve quality, reduce scrap, rework and customer rejections. Conducted Run at Rate (T1-XX steering knuckle for GM) to verify production output to identify bottle necks and total yield. Reviewing the drawings and requirements and especially reviewing the GD&T features on Drawing and calculating the bonus tolerances. Conduct Gage R&R for both attribute and continuous/variable data, analyzed results and applied lean principles on the shop floor to reduce various forms of wastes (Excessive time/motion). Perform RCCAs (Root Cause and Corrective Actions) on CMM (Coordinate Measuring Machines) nonconformance reports on produced castings. In development, improved initial low yield by examining root causes and conducting DOE to determine optimum mold cavity size. Led comprehensive risk assessments and developed process and design FMEA's for Aluminum Counter Pressure Casting. Continuous Improvement Projects

Designed process changes during a major overhaul of the on-site aluminum melt furnace, Result in reduction of process time by 45-50%. Implemented FIFO system for achieving continuous flow and reduced downtime by 33% and reduced the number of scheduling points. A 24-hour kaizen event was developed to track all issues in Counter Pressure Casting machines by operators. Factors that were affecting continuous cycle time in the process were fixed and OEE improved drastically. Increased throughput up to 35% by suggesting the optimal build sequence, operator manning pattern and buffer strategies