Summary
A results-driven Lean Manufacturing Specialist with 6 years of experience in optimizing production processes, enhancing operational efficiency, and driving continuous improvement initiatives. Expert in applying Lean methodologies, Six Sigma principles, and data analytics to reduce waste, improve quality, and increase throughput across diverse manufacturing environments. Proven ability to lead cross-functional teams, implement strategic improvements, and deliver significant cost savings and productivity gains.
Experience
Senior Lean Manufacturing SpecialistFord Motor Company
- 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
- 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.
Projects
Digital Twin for Assembly Line Simulation
- 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
- 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
- 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.
Education
Georgia Institute of TechnologyMaster of Science in Industrial Engineering
- 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
- 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%.
Publications
Applying Lean Six Sigma to Reduce Variation in Automotive Paint Shop Operations
A Comparative Study of Kanban and CONWIP Systems in High-Mix, Low-Volume Production
Integrating IoT for Real-time OEE Monitoring in Discrete Manufacturing
Skills
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