Mayank Sharma

Experience

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  Ashok Leyland

  May 2010 - Jun 2010

  Summer Intern

  • Validated machine equipment and conducted production try-outs on a new line of chassis assembly shop• Supervised machinery installation and prepared reports of the trial runs on them

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  Maruti Suzuki India Limited, India (Parent company - Suzuki Motor Corporation, Japan)

  Jun 2011 - Mar 2014

  Assistant Manager, Manufacturing Engineering

  PROCESS AND QUALITY IMPROVEMENT:• Led continuous improvement activities; coordinated a cross functional team and achieved 2% increase in yield in a Lean Manufacturing environment• Introduced centrifugal type pumps in all the machines; leading to an increase of 2% in Overall Equipment Effectiveness(OEE)• Applied lean tools; led a PDCA team consisting of personnel from maintenance, facility planning and production to analyze the root causes of downtime, design & quality issues and implemention of countermeasuresNEW PRODUCT DEVELOPMENT AND OPTIMIZATION:• Coordinated new product introduction and development; served as a liasion for change management, made necessary changes in the robotic movements, machine program and equipment changeovers, reducing cycle time by 15%• Established adequate quality control for the parameters of a process using APQP, DFM/A• Planned man, machine and material availability for the on site try outs/trialsCOST REDUCTION, ERGONOMICS AND SAFETY IMPROVEMENT:• Proposed and implemented a Kaizen to reuse the scrapped plunger sleeves; leading to a cost savings of $12500 per year• Designed, fabricated and automated a runner crushing machine; leading to the reduction of trolley movement by 75% and improving ergonomics and safetyPROCESS DOCUMENTATION AND REPORTING:• Responsible for the internal auditing of the process as per the ISO compliance• Responsible for the documentation of ECN, process change manuals, machine and operator instruction sheets• Generated weekly, monthly and yearly reports of the top Key Performance Indicators(KPIs) of the departmentTRAINING AND EVALUATION:• Led a team for the setup of training room through a complete tear down of 24 tons of cylinder block die; scheduled training for operators and supervisors• Facilitated brain storming sessions of the supervisors for the identification of cost reduction ideas in engine casting, machine and engine assembly shops Show less

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  Briggs & Stratton

  Jul 2015 - Dec 2015

  Manufacturing Engineer Co-op/Intern

  • Installed, programmed and integrated a 50W, 3 Axis Keyence Laser Marking system on the assembly line; coordinated with vendors for installation and integration with line• Contributed in a cross - functional team/ system development team; created and implemented design for manufacturing solutions for an assembly pallet validation process, and increased uptime by 1%• Coordinated the validation and qualification(IQ, OQ & PQ) of newly installed assembly automated machines through time studies, repeatability studies and data analysis(Cp, Cpk)• Participated in the sourcing activities like specification creation, release to vendor, quote technical evaluation, and procurement of the enclosure unit and its associated parts• Designed, developed, procured and installed a single axis cylinder mounted gated system for the enclosure unit of the Laser system• Successfully integrated the engine tracking barcode system with the bill of material to eliminate any mismatching of the components in the assembly• Prepared standard operating procedures for training of personnel regarding the operation and troubleshooting of the laser machine Show less

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  Northeastern University

  Dec 2016 - Feb 2017

  Volunteer Research Assistant
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  TeraDiode, Inc. - A Panasonic Company

  Feb 2017 - Sept 2019

  Manufacturing Engineer

  • Prioritized and led many continuous improvement projects to improve productivity by 3 times within 12 months.• Managed and completed various six sigma projects, applied DMAIC, conducted extensive data analysis and FMEA, implemented short and long-term corrective actions, and improved yield by 15%.• Conducted detailed time studies and generated an automated capacity model to eliminate wastes and utilize manpower and work stations efficiently.• Coordinated with domestic and international vendors to support operational qualification, installation qualification and performance qualification.• Established routing times for all the manufacturing processes in the ERP system and analyzed the differences between existing and new cost levels.• Worked in cross functional teams and developed Key Performance Indicators (KPIs) and statistical process control parameters.• Introduced new work instructions and updated existing ones with detailed process mapping.• Driven ECO changes and led process documentation of all the manufacturing processes in the area. Show less

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  Amazon

  Oct 2019 - now

  Strategic planning to support capacity engineering in a fast growing Amazon Logistics North American (AMZL NA) network.

  • Senior Operations Engineer/Senior Program Manager

    Oct 2021 - now

  • Program Manager

    Oct 2019 - Sept 2021