Nikolay Ganchozov

Experience

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  EXPAL (MAXAM Group)

  Dec 2012 - Feb 2016

  - Participant in project for new production line for recycling of metal parts of ammunition;- Ordering appropriate machines, equipment, tools and devices for recycling metal parts(like lathes, blasting machines and etc.);- Design gauges, devices for measurements, equipment for recycling metal parts of ammunition;- Communicate and ordering designed equipment for producing at external factories;- Design spare parts for machines;- Defining work parameters of the production equipment;- Control over correct performance of processes;- Defining material consumption for recycling of ammunition;- Developing processes for assembling;- Process hazard analysis ( HAZOP, WHAT IF);- Implementing some of principles of lean manufacturing;- Developing process maps, layouts, work flows and etc;- Researching information about ammunition for demilitarization;- Developing work instruction and operating practices for demilitarization of different kind of ammunition according health and safety rules and best practices;- Transferring processes from other Expal factories;- Report progress of projects to engineering department of headquarters;- International tasks;- Conducting different kinds of experiments to reach the goals;- Staff training; Show less - Researching information about ammunition for demilitarization;- Developing work instruction and operating practices for demilitarization of different kind of ammunition according health and safety rules and best practices;- Developing process maps, layouts, work flows and etc;- Design tools and devices necessary for demilitarization;- Control over technological processes;- Order equipment, tools, devices;- Defining material consumption;- Contribute to health and safety analysis; Show less

  • Process Engineer and Equipment Designer

    Jul 2014 - Feb 2016

  • Process Engineer

    Jun 2013 - Jul 2014

  • Internship Process Engineer

    Dec 2012 - Jun 2013
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  Sensata Technologies

  Mar 2016 - Oct 2017

  Process Engineer

  Supports production in daily engineering activities;• Supports process development for New Product Development projects on existing processes;• Provides training for operators and technicians on process and equipment related knowledge; • Establishes and maintain process documentation including Working Instructions / FMEA / Control Plan / process flow / SOP;• Continuously improves process capability. Continuously improves process through-put, cost effectiveness and process quality as part of operation excellence (yield, productivity, OEE, Poka-yoke);• Interfaces with quality team, designer and mechanization team on process and product optimization.• Conduct experiments and analysing results to define better process performance;• Laser welding and crimping processes; Show less

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  APS GROUP - Advanced Printing Systems

  Oct 2017 - Dec 2017

  Process Engineer

  - Implementation of Hot bar soldering process (FPC to PCB);- Adjusting and maintenance hot bar soldering machine;- Ordering spare parts;- Collaboration with Design Engineers for necessary parts which has to be designed;- Conducting different kind of experiments with different materials and process parameters to define best process output with least variation;- Installation of CNC machine(X, Y, Z) with dispensing equipment. Programming for different products and implementation in mass production;- Implementation of automatic UV glue dispensing process;- Define parameters for UV conveyor system for curring UV glue;- Preparing WI, Validation reports;- Process auditing and validation of new suppliers processes in order to ensure required quality;- Adjusting and implementation of 3 layers pad printing machine. Set up of vision inspection camera which check print quality;- Training the operators of new processes;- Proposal new low cost materials; Show less

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  Sensata Technologies

  Dec 2017 - Jan 2019

  Process Engineer

  Medical device production for GEHC customer;- Develop and implement process for applying silicone sealing(this include ordering gun for dispensing silicone, design fixture to attach gun to XYZ CNC machine, conducting test to define the best process parameters which meet geometrical requirements, programming the machine to follow complex cordinates, preparing validation report for machine and its parameters, preparing work instruction, training operators, implement 5S, defining zones for incoming and out going products, NOK parts and suspected parts);- Develop Work Instruction(all operations on line);- Training operators on new processes;- Desing tools, trays, holders and fixtures and prepare processes with designed items;.- Ordering necessary equipment and tools(like standard manual tools, electrical torque control tools, manual torque control tools);- Conduct experiments to define the best torque for different kind of screws in order to control the process of screwing, reducing scrap rate due to damaged threads and etc.;- PCB analysis for quality of solder joints; - Solving production issues occurred in process;- Participant in international team which fully modify line for production joysticks(this include implementation of one piece flow, defining work zones, incoming and outgoing zones, create buffer WIP, re-arrage work place, measurement and calculating times in order to balance the line, reduce time for production and etc, implement board for daily tracking production);- Collaboration with Design, Quality, Planing, Supplier Quality departments, External suppliers, colleagues from other sensata locations;- Reviewing of costumer non-conformance and implement corrective actions;- Following list of actions defined in Kaizen events;- Implementation of kan-ban system for high running components;- CAR preparation; Show less

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  KOSTAL Group

  Jan 2019 - May 2021

  Engineer of Production planning, Forecasting and Development

  Production of spiral cassettes and sub-assemblies for BMW steering column modules(Achieved results during responsible of project = 160K BGN/Year); - Leading transfer of exiting and new production lines from Kostal Czech Republic to Kostal Bulgaria; - Planning of layout, capacity, operators, line balancing; - Preparing all documents according QMS for manufacturing parts; - Managing events for trail runs and validation of lines; - Responsible for automatic and semi-automatic production lines from 4 to 20 operations per line(assembling, pressing, electrical testing, resistant welding, hot and cold caulking, cleaning, greasing, PCF cutting, cutting die, laser labeling, vision control systems); - Collaboration with Quality, Production, Maintenance, Design, Logistic, H&S, Accounting, Automation, Facility, Tool shop, Purchasing and Project management departments; - Plan, organize and imlement improvements in production processes(reduce scrap rate and downtime, increase productivity); - Daily tracking of KPI and proposal corrective actions in order to improve it; - Impelementation new product in production processes; - Request necessary resources to project; - Order spare parts; - Manage technical documentation of the lines; - Develop concepts of improvements and plan it realization in order to solve repetitable issues; - Responsible for BOMs and Rountings accuracy; - Transfer and start up production equipment for producing steering column modules and its sub-assemblies for DAIMLER MFA2; - Leading implementation of Engineering Change Management programs; - Monitoring and control of processes; - Project management; - Participate in preparation of audit; - Suggests, cooperate and support the implementation of procedural changes; - Technical support of production and maintenance with focus to processes; - Track progress of assigned project; - Participant in international teams; - PDCA and DMAIC;- Solving PLA and 5s audit nonconformities; Show less

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  Sanmina

  Jun 2021 - Oct 2023

  Lean Coordinator

  - Testing of new materials for coating pcbs and preparing reports;- Implementation of floor marking color codes and legends;- Maintaining factory layout;- Implementation of lean and six sigma program across the factory;- Implementation and execution of 5S program;- Defining training plans and needs;- Induction training of new hires over LSS and 5S Programs;- Training of line leaders and management team; - Managing LSS database with projects and kaizens;- Participate in monthly divisional LSS meetings;- Support project teams with usage of lean tools;- Calculating project values(project cost savings);- Organizing monthly lean and six sigma meeting with the management team; - Weekly report to General Manager over LSS progress;- Leading project and kaizens; - Develop and implement employee suggestion scheme(idea collection); - Develop reward and recognition program; - Implementation of automatic IoT production monitoring system;- Support production and project teams with lean tools usage; - Auditing 5S+ zones;- Line balancing; - SMED;- Support new line installation;- Participating in various projects ( -implementation of AGV, Reduction of N2 consumption, reducing cost for chemical usage and etc).- Achieved savings 300k USD. Show less

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  Willi Elbe Automotive Bulgaria

  Nov 2023 - now

  Process Engineer