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Experience Snap Shot Rajat Debgupta Industrial & Manufacturing Engineering  University of Windsor Employment Scope: Indust...
Management Skills and Techniques <ul><li>Task Identification, Delegation and Follow-up </li></ul><ul><li>Team Player and L...
Facilities & New Equipment Management <ul><li>Purchase & quote equipment, and run off new equipment for production systems...
Launch & Program Management <ul><li>Cross Functional Team Management </li></ul><ul><li>New Business Launch  (Total Minivan...
Documentation Management <ul><li>Standard Work Instructions and Procedures - QS procedure, ISO procedure </li></ul><ul><li...
Product Development/Launch – Process Planning & Tooling Allocation <ul><li>Faurecia IS 2006 Sebring & Avenger Instrument P...
Major Project Undertaking - 1 <ul><li>Gerber Cutter Uptime Study (3 Cutters) – Delay Study and Motion Study – 20% increase...
Major Project Undertaking - 2 <ul><li>Reduction in Conveyor Downtime & Developed Controls SOP for Users – Lean & Six Sigma...
Shop Floor & Process Flow Improvements <ul><li>Development of AutoCAD Layouts for Space Optimization and Time Studies and ...
Process Improvements Techniques <ul><li>Motion & Delay Time Studies and MOST </li></ul><ul><li>Layout Optimization (AutoCA...
Training & Certifications <ul><li>ISO 14001 Internal Auditor Certified </li></ul><ul><li>TS 16949:2002 Internal Auditor Ce...
Accomplishment Highlights <ul><li>15% Labor Reduction per year = $12M Cost Save to Company (DCX) </li></ul><ul><li>Elimina...
Personal Attributes <ul><li>Self Starter, Dependable, Reliable </li></ul><ul><li>Trustworthy and Approachable </li></ul><u...
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Experience Snap Shot Presentation (Design 3)

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This is my experience snap shot (as I call it) to get a better feel of what I have done and been exposed to over the years. I plan on constantly polishing this up for better presentation - for now this is what I made. Would appreciate any queries and comments on this. Thank you.

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Transcript of "Experience Snap Shot Presentation (Design 3)"

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