Fatima Hassan | Senior Lean Manufacturing Specialist at Ford Motor Company

Summary

Senior Lean Manufacturing SpecialistFord Motor Company

Dearborn, MIJun 2021Present

Led 15+ Kaizen events across assembly lines, resulting in a 25% reduction in cycle time and a 10% increase in daily production output for key models.
Implemented a new Kanban system for material flow, decreasing inventory holding costs by $1.2M annually and improving material availability by 18%.
Coached and mentored production teams on 5S principles and visual management, achieving a 30% improvement in workplace organization and safety compliance scores.
Developed and deployed standard work procedures for critical operations, reducing defects by 15% and rework by 20%.
Managed a capital project to upgrade automated guided vehicles (AGVs), improving internal logistics efficiency by 22%.

Lean Manufacturing EngineerGeneral Electric Aviation

Evendale, OHJul 2018May 2021

Analyzed production data to identify bottlenecks and waste, leading to the redesign of two major production cells and a 15% improvement in overall equipment effectiveness (OEE).
Facilitated value stream mapping workshops for engine component manufacturing, identifying opportunities that saved $850K in operational costs over two years.
Designed and implemented error-proofing (Poka-Yoke) solutions, reducing assembly defects by 12% and associated warranty claims by 5%.
Trained 100+ employees on Lean tools, including SMED and TPM, which collectively reduced changeover times by an average of 30%.
Collaborated with R&D to optimize new product introduction processes, accelerating time-to-market by 10% for two critical aerospace components.

Developed a digital twin model of an automotive assembly line using Arena Simulation, identifying optimal buffer sizes and resource allocation.
Simulated various production scenarios, predicting a 7% increase in throughput and a 5% reduction in WIP inventory through optimized sequencing.
Presented findings to senior management, influencing a $500K investment in line rebalancing and automation upgrades.

Supplier Quality Improvement Program

Jan 2020Dec 2020

Led a cross-functional team to assess and improve critical supplier quality, resulting in a 15% reduction in incoming defect rates.
Implemented a new supplier audit process based on Lean principles, improving on-time delivery by 10% and reducing material rejections by 8%.
Collaborated with suppliers to establish joint continuous improvement initiatives, fostering stronger partnerships and shared quality goals.

Ergonomic Assessment and Workspace Redesign

Jun 2019Nov 2019

Conducted comprehensive ergonomic assessments for 3 manufacturing workstations, identifying high-risk tasks.
Redesigned workstations with adjustable fixtures and improved tooling, reducing reported musculoskeletal discomfort by 25%.
Decreased worker compensation claims related to ergonomics by 18% within six months of implementation, improving employee well-being.

Georgia Institute of TechnologyMaster of Science in Industrial Engineering

Atlanta, GAAug 2016May 2018

Specialized in Supply Chain and Logistics, maintaining a 3.8/4.0 GPA.
Thesis: "Optimizing Production Line Layouts for Flexible Manufacturing Systems."
Awarded Dean's Fellowship for academic excellence.

Wayne State UniversityBachelor of Science in Mechanical Engineering

Detroit, MISep 2012May 2016

Graduated Magna Cum Laude with a 3.7/4.0 GPA.
Member of the Society of Manufacturing Engineers (SME).
Capstone project: Designed an automated inspection system for automotive parts, reducing inspection time by 15%.

Lean Methodologies

Value Stream Mapping5SKaizenKanbanSMEDPoka-YokeTPMJust-In-Time (JIT)

Process Improvement

Six Sigma (Green Belt)Root Cause AnalysisStatistical Process Control (SPC)Process Flow OptimizationWaste ReductionContinuous Improvement

Data Analysis & Tools

MinitabExcel (Advanced)SQLTableauPower BIArena Simulation

Manufacturing Operations

Production PlanningSupply Chain OptimizationInventory ManagementQuality AssuranceAutomationRobotics

Project Management

AgileWaterfallMicrosoft ProjectJIRACross-functional Team Leadership