Karan Bhadane, PMP®, LSSBB

Experience

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  Mahindra Sona Limited

  Jun 2014 - Jul 2015

  Trainee and Intern

  - Practical implementations facilitated the learning of concepts like Design and Safety, Manufacturing, Productivity Management/Improvement, Kaizen, Poka-yoke, 5S, 8D, PFMEA, DFMEA, etc.- Assisted manager in meeting quality targets and leveraging lean tools to streamline the manufacturing processes. Reduced WIP by 22% by identifying areas of bottlenecks and Kaizen burst by mapping value stream in Visio for an assembly and raw material receiving station.- Monitored process and their performance to ensure efficient and problem-free operation with increased in workers’ safety.- Completed periodic line checks, troubleshooting and resolve issues to determine compliance with the product specification.- Beneficial in accomplishing critical and complex tasks with optimization of waste, substantial reduction process time with the use of time and motion study, Lean tools, DMAIC and 8D approach.- Conducted time study on the sleeve and slip yoke production line and analyzed the breakdown of value and non-value adding activities.- Studied the process workflows and performed root cause analysis of the system. Show less

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  Siddha Engineering Works

  Jul 2015 - Jul 2016

  Manufacturing Quality Engineer

  - Planned and coordinated manufacturing engineering processes daily, resulting in high quality products. - Led and facilitate process improvement teams providing Lean tools such as Pareto charts, process flow charts, Value Stream Mapping, A3 Reports, basic statistics, control charts, and Lean Daily Management (LDM).- Utilized Lean and Six Sigma principles to ensure that manufacturing requirements for efficient processes and practices are addressed on a timely basis.- Improved the productivity by 15% and reduced the overtime by 9% by performing line balancing to suffice present and future demand.- Aided in performing pre-production inspections, ensuring scrap less than 9% for the set-up change and 5% for daily production.- Utilized problem solving methodologies to determine root causes of problems and assisted facilities to implement effective and sustainable solutions.- Modeled production systems during decision making process using math and statistics. - Identified and implemented standard operating conditions and resolve system malfunctions to limit potential operational problems.- Developed best practices to improve production capacity, quality and reliability. Show less

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  Auburn University

  Jan 2017 - May 2017

  Graduate Teaching Assistant

  Graduate Teaching Assistant for Statistics and Probability Course in Industrial and Systems Engineering Department.- Mentored and advised undergraduate students. Prepared and graded assignments. - Collaborated with professor on deciding course and grading policies.- Designed presentations for in-class and online lectures and tutored students on ‘Minitab’ (a statistics software package).

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  O-Flex Group, Inc.

  May 2018 - Jul 2018

  Quality Engineer

  As Quality Engineer, I navigated and led the overall Quality process Design and Quality performance of roof rails for BMW, Ford, Mazda, Nissan, General Motors, Chrysler, Toyota, Honda, and Volvo. I met and exceeded expectations by identifying customer needs and developing/enhancing plans to meet those quality-focused needs.- Met and exceeded customer demands and expectations and maintained focus on project schedule by implementing Design of Experiments (DOE) to identify the root cause of problems and mitigative solutions.- Accommodated urgent and routine change requests for parts already in production without interruption to the project lifecycle.- Met customer-specific requirements by establishing and modifying operations standards, work instructions, OEM, and PPAP requirements.- I held strict accountability for analyzing and updating process flow diagram, PFMEA, Control Plans, and applied Statistical tools, DMAIC methodology, Gage R&R, to shop floor processes.- Exhibited excellent critical thinking, organizational, and prioritization skills while collecting and analyzing statistical data, reducing process scraps/rejects, and increasing efficiency.- Successfully utilized Six Sigma and Lean Methodologies to improve customer communication and support project activities, including process improvement and corrective actions. Show less

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  Bolta US

  Jul 2018 - Apr 2022

  Automotive Program Manager

  As Automotive Program Manager, I oversee, lead, and direct planning and transfer activities aligned with the plant and project development team's objective. - Champion successful strategies to deliver on the customer experience and client satisfaction, and project excellence by completing the project within ten (10) weeks.- Successful in triggering a 15% increase in productivity, exceeding customer demand, by reorganizing the assembly line; I performed line balancing techniques and trained the operators while leveraging Lean Manufacturing Principles to implement continuous process improvement measures.- Demonstrate authoritative leadership and the ability to manage, influence, and communicate with external business partners, OEM customers and their decision-makers, and internal teams.- Handling a wide range of functions, including support complex tool transfers related to the Injection Molding and Electroplating process; providing technical support, including technological approach development and troubleshooting; and delivering unparalleled support to the development team, as well as production and logistics activities and functions. Show less

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  Walmart

  Apr 2022 - now

  Senior Project Manager