Vijay Krishnan

Experience

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  Ashok Leyland

  Dec 2012 - May 2013

  Project Intern - Lean Team

  • Worked with Lean Team in Axle Beam Manufacturing Plant of a Heavy Vehicle Manufacturing Industry in order to develop an optimum design of axle beam to improve the quality of Axle Beam manufactured in the plant.• A standard design using Geometric Dimensioning and Tolerancing (GD&T) system and Auto CAD software was developed, and based on DFM and DFA techniques, the existing design was optimized to facilitate manufacturing and ensure better performance. Also, Variation Analysis was performed on different samples of Axle Beam provided by various suppliers to reduce variation in product specification. This led to improvement in design & quality of the product, increase in overall performance of the product and better customer satisfaction. Show less

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  Defense Logistics Agency (DLA)

  Aug 2014 - Dec 2014

  Team Member

  • Designed & developed an optimized process flow simulation for different food items in a packing process using Auto CAD & Autodesk 3D Models, and implemented six sigma methodology to reduce defects in production and improve the packaging quality of finished products. • This project led to assembly line balancing, reduction in process variation, effective throughput, assured better inspection, and improved packaging quality.• The simulation model served as a training module to train plant personnel, and also as a quality control tool for the employees to organize and pack the food items in an efficient and reliable manner. Show less

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  University of Tennessee

  Aug 2014 - now

  Graduate Research Assistant

  • Evaluated the challenges involved in manufacturing plan and work sequences using Root Cause Analysis, Value Stream Mapping technique and Dynamic Programming Methodology.• Performed constraint and sensitivity analysis on different scenarios to balance the production line, and identify the optimum working conditions in order to achieve the annual production target.• Proposed & implemented an innovative lean manufacturing system using simulation, which provides technical support and training to guide changes on scaling up the current manufacturing process with improved production performance, reduced cycle time, enhanced process reliability, improved throughput, reduced process variability, minimum WIP, downtime maintenance, effective resource utilization, balanced workforce, improved quality, and safety.• Also, a Performance Measurement System with Key Performance Indicators (KPI’s) was developed to monitor, evaluate and manage the test results and quality data to ensure expected performance of the system at different levels (Thesis). Show less

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  Johnson Matthey Catalysts

  May 2015 - Jul 2015

  Project Intern

  • Led a team of 11 engineering students and completed two projects related to Lean & Reliability in a Large Scale Chemical Manufacturing Industry.• Using value stream mapping, identified the ergonomic constraints in the process flow. Implemented 5S and floor space optimization methods to increase the process yield by 26% and reduced the manual work by 19.8%.• Scenario Analysis using simulation was performed to determine efficient flow of the process, impact of setup reduction, effective yield, and optimum working conditions, required logistics & layout design, and cost of operation. Show less

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  Covenant Health

  May 2015 - Jul 2015

  Team Member

  • The aim of this project is to statistically analyze wait time and length of stay of patients in the Emergency Department in order to optimize the overall process with respect to length of stay (LOS) and improve the quality of service offered to patients. • Developed a lean patient flow simulation model which predicts the wait time & length of stay of patients in the system using Root Cause Analysis & Dynamic Programming approach. • Additionally, this model helped to determine and evaluate the utilization of different resources in the system. (Registered Nurse, Physician, Emergency Room, Triage Nurse, etc.) Show less

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  Techmer PM

  Jun 2015 - Jul 2015

  Project Lead – Lean Summer Program

  • Led a team of 11 engineering students & completed two projects related to Lean & Reliability in a Colorants and Chemical Additives Manufacturing Industry• Developed and established a Sustainable Culture & Recycling System for Waste Management. Performed root cause analysis to determine the main causes for recyclable waste being sent to landfill, and ergonomically redesigned locations of bins in production facility based on employee satisfaction survey. Also, a rewards system was introduced to encourage the recycling habit of employees. This project led to 25 % reduction of recyclable waste being sent to landfill annually.• Standardized the Samples Shipment Process in order to balance the workload among other departments. Performed value stream mapping to identify non-value added activities in the process and then proposed the new system for shipping the samples by involving various departments which resulted in elimination of 35 hours of non-value added time per month. Show less

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  Xtreme Tower Products

  Mar 2016 - May 2016

  Engineering Intern

  • Performed time studies for different tower assembly operations within assigned area and proposed cycle time reduction methods to improve efficiency and reliability of the process. • Trained Team Leaders to Develop & Implement standard operating procedures (SOP) in production areas to improve process flow, reduce variation & disruption, improve product quality and ensure safety. • Also, worked with customers to ensure the product meets required quality with expected level of performance. Show less

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  Great Lakes Boat Top

  Jun 2016 - Jul 2016

  Project Lead - Lean Summer Program

  • Supervised a team of 25 engineering students from different countries (Brazil, Mexico, and China) & completed five projects related to Quality Control, Product Design & Development, and Lean & Reliability in a Boat Manufacturing Industry.• Different projects dealing with product design, ergonomics, process flow automation in a warehouse, and plant layout optimization were approached using lean tools like 5 Whys, Root Cause Analysis, A3, and DRIVES model.• Analyzed each operation within assigned area for Ergonomic and Safety concerns. Designed material delivery racks and work tables to improve the ergonomics of production line worker. Also, designed a lean layout to facilitate better material storage and reduce the non-value added move time of workers in the plant.• These projects established a system to automate, monitor, collect, and retrieve data directly from shop floor to be used by the management. Also, identified the responsibilities for each management level to effectively train employees in the system.• 5 Whys methodology was followed to address 68% of the customer complaints with respect to design of a particular product.• Identified the quality problem attributed to current design and developed an innovative and user-friendly solution that meets the requirements of the customer using A3 methodology. The product design was developed based on Design for Manufacturing (DFM) and Design for Assembly (DFA) techniques using Auto CAD and Autodesk Inventor software. Finally, the product design was evaluated using DFMEA (Design Failure Mode and Effect Analysis). Show less

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  Maine Medical Center

  Oct 2017 - now

  • Quality Management engineer

    Oct 2019 - now

  • Project Manager

    Oct 2017 - Sept 2019