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Manufacturing Process Engineer

Seguin, TX


  • Over 5 years of Assembly and Product experience in Manufacturing domain
  • Responsible for new product introduction, assembly process planning, line balancing techniques, customer improvement action and scheduling concepts
  • Profound knowledge on Lean manufacturing, APQP, Simulation, Six sigma methodology and Quality control
  • Expertise in Lean implementation to increase throughput, reduce production cost and cycle time
  • Certification in Lean and Six sigma green belt
  • Proficient in ProE, Plex ERP, Caterpillar HVC (2D), Team center visual mockup (3D), Time and motion
study, Process engineering, Standardized work, Engineering change management, CDSA and AutoCAD
  • Versatile in quantitative, analytical and decision making skills with sound knowledge in logistics, labor utilization standards, cost analysis system and ability to monitor various individual projects
  • Hands on experience on shop floor, participating in Kaizen, Quality Assurance and TQM programme
  • Worked as a Graduate Research Assistant handling Activity Scheduling Research project.

Work Experience

Manufacturing Process Engineer

Axis Inc. (Seguin Engine Plant), Seguin, TX

Nov 2010Current

  • Responsible for Assembly process planning ODS/ EDS using plex ERP for C15, C13 and C9 Caterpillar Engines delivered to CAT Brazil, CAT East Peoria, CAT Lafayette, Perkins UK and Oshkosh Trucks
  • Involved in Line balancing of Application and ATA-APA workstations, Virtual builds for NPI using Siemen Vizmockup team center, use of CAT material spec 1E0279 and follow up of pilot validation engines
  • Expertise in Tool program, subassembly triggering, Process routing, Engineering change requirement, control plans, PCN, BOM, troubleshooting to WINCC simatic display workstations and Job manager
  • Strong exposure to torque tools like GCI Arms, ETV, ETP, Atlas copco transpulse, ST wrench, Multispindle, lifting devices and battery operated guns
  • Resolved issues related to subassembly build on Fuel filter base, Oil filter base, Oil coolers and NRS coolers.
  • Worked on a successful Engine shipped order fan drive project for both C15/C13 Application line
  • Worked on PFMEA and control plans, root cause analysis and customer improvement cards.
  • Involved in Engineering line support with expertise in troubleshooting issues reducing downtime

Manufacturing Engineer, JCI

Avanzar Interior Technologies,

Sep 2010Oct 2010

  • Handling of Supermarket planning tool, line balancing, value stream mapping and work flow analysis
  • Majorly involved in routings, work and time study

Industrial Engineer

Texas A & M University, TX,

Aug 2007Aug 2009

  • Research Project 2: Lean Project with Dr. Hong Zhou on transformation of traditional kitchen into lean cafeteria
  • This transformation employ's various lean principles like value stream mapping, work flow analysis, line balancing, layout and work cell design, 5S's and visual workplace
  • This transformation results in ergonomically superior workplace
  • Reduced cycle time and needless conveyance increasing productivity, efficiency and effectiveness in work procedure

Manufacturing Engineer

Rotex Automation Ltd,

May 2006Jul 2007

Manufacturing of Pneumatic products like Cylinder, Actuator and Solenoid Valves using Lean concept
  • Production Planning: Performed planning weekly on 5M ERP, updating BOM, Ensuring Production as per the plan and meeting Production targets, Man Power Planning
  • Lean Activities: Increased throughput of pneumatic assembly line by 18% through value stream mapping (VSM) & 5S worked on flow Lean concept to cut labor cost, lead time, machine waiting time at assembly line, results achieved after lean implementation are 40% improvements in manpower, 14% improvement in cycle time, 72% in total product travel length and 15% in production lead time
  • Process Improvement: Reduced lead time in the Actuator department by 26% by eliminating non-value added activities. Implemented FMEA chart reducing risk priority number from 420 (S6, O7, D10) to 48 (S6, O2, D4)
  • Line Balancing: Maximized the workload smoothness and reduced the takt time by 12%
  • Documentation: Prepared detail standardized work sheet (SOP), FMEA and Control Plan for all processes
  • Brainstorming: Communicated with all team members and other groups within the company to improve performance of the design team to meet the project deadline

Manufacturing Engineer

Blue Star Ltd,

Jun 2004May 2005

Manufacturing of Split, Window Air Conditioner, Central Air Handling Unit and Recipe Chillers
  • Planning Activities: Responsible for carrying out capacity analysis, BOM and improving current process
  • Performed production planning of 1500 insulated door panels assigned for 4 workers in 1 shift
  • Performed time and motion studies for Capacity planning and Manpower planning
  • Prepared and documented APQP, PPAP, Planning sheet, Routing sheet, Standardized Work Sheet (SOP), FMEA, Control Plan and Process Mapping as per ISO 9000, OSHA and TS 16949 Standards
  • Interacted with vendors for packing and delivery methods for the Air Handling Units
  • Duties and Projects: Supervised and trained employees, prepared daily reports and managed other shop projects
  • Responsible for project on designing and manufacturing of door fixture reliability from scrap metals adding kaizen to the company
  • Lean Mfg: Improved productivity and work place using 5S techniques, Kaizen, JIT & TPM system
  • Improved productivity of Feeder Shop line by 25% through reduced set up changes & Poka Yoke
  • Reduce defects in the after production door panels by placing in a fabricated rack, hence increase in quality through 5s implementation
  • Accessed flow of raw material sheets in assembly line through Value Stream Mapping by improvement in 5% lead time and implemented Tool Management system through 5S & Kanban, saving $20,000/yr
  • Reviewed value added engineering suggestions for new products resulting in a savings of $48,000/yr

Study on Co-ordinate Measuring Machine and their Application
  • Analysis of different contact and non-contact sensor probes
  • Collected data, analyzed application of laser scanners depending on scanning points per second
Computer Simulation on Toyota Production System
  • Simulation on daily production analysis of 30 manufactured vehicle by using Arena software
  • Used simulation models like entities, attributes, variables and queues
  • Seminar Presented:
    • Lean Manufacturing in Pen Industry, Texas A & M University, TX
    • Literature Review-Enterprise Integration, CIM and future trends. TX

    • Manufacturing: Lean Manufacturing, Inventory Management, Simulation using Rockwell Software Arena
    • Supply Chain: Supply Chain Management, Optimization Research
    • Production: Activity Scheduling, Manufacturing System Design, Computer Integrated Design and Engg Economics
    • Quality: Six Sigma, ISO 9000, Professional of Management, Total Quality Management


Master of Science in Industrial Engineering

Texas A & M University, Kingsville, TX


Bachelor of Mechanical Engineering

University of Mumbai, Mumbai, Maharashtra



Lean manufacturing, Six sigma green belt, Team center Vizmockup,

Additional Information

  • Simulation Software: Arena 7.01, Minitab, Win Runner, iGrafx, Vizmockup Team Center
  • Certification: lean, six sigma green belt
  • Member: and IIE
  • Utilities: 5M ERP, AIS, MCS, HVC, Auto Cad, ProE, Solid Works, C Programming, Microsoft Application
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