Mohammed Faisal

Experience

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  Ford Motor Company

  Jan 2015 - Mar 2015

  Mechanical Engineering Intern

  Alleviated problem related with the Ski-bar.•Completely analyzed design aspects.•Worked in a team consisting of four people.•Helped the factory cut costs in manufacturing.

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  Indratech LLC

  Jun 2017 - Aug 2017

  Industrial Engineering Intern

  Recruited as an Industrial Engineer to:• Use Statistical Process Control to monitor KPI's.• Ensure proper utilisation of labour resources.• Improve inventory tracking and reduce inventory storage costs.• Analyse and improve Overall Equipment Efficiency(OEE) and downtime data to detect various losses in manufacturing process.

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  Advanced Assembly Products, Inc.

  Aug 2017 - Dec 2017

  Quality engineering intern

  Recruited as a Quality Engineer to:• Focus on Supporting manufacturing by guiding, training and covering floor receiving, shipping and manufacturing activities to reduce customer exposure and excessive internal waste.• Lead key inputs to the APQP, MSA and PPAP processes.• Lead floor audit activities and action plans.• Interface with key internal and external partners to champion corrective action plans and validation of action effectiveness.• Verify equipment used for part validation of action effectiveness.• Provide key trend data as an input to PFMEA and control plan updates.• Implement/Update process documentation including visual aids and labelling to control and reduce quality risk. Show less

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  Indratech LLC

  Jan 2018 - Feb 2020

  Quality & Continuous Improvement Lead

  ● Supported daily operations to ensure that products and processes complied with the relevant requirements of the quality management system.● Point person at plant level for customer communication regarding actions taken for corrective actions.● Maintained ISO 9001:2015 standard and assisted corporate quality in establishing, implementing and maintaining the quality management system. ● Implemented Overall Equipment Efficiency tracking to monitor and improve process efficiency. ● Achieved $40,000 annualized saving by working with vendors on an adhesive-reducing cost by 32% per pound.● Developed a plant layout for upcoming facility.● Incorporated Six Sigma methodologies to solve design and manufacturing problems. ● Ensured products are conforming to customer specification and ISO standards.● Identified and analyzed risks associated with the process using PFMEA: ensuring smooth flow of the process.● Worked with program management for PPAP submissions.● Verified calibration of instruments necessary for validation; check fixtures and gages.● Implemented and analyzed Key Performance Indicators to evaluate success of a process.● Used Root Cause analysis and 8D methods to solve recurring problems.● Conducted time studies to identify bottle necks and improve throughput.● Managed Quality metrics and presented findings and recommendations to upper management.● Worked with suppliers to identify root cause and implement corrective actions to ensure quality of products meets customer requirements. Show less

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  LEER Group

  Feb 2020 - Dec 2020

  Continuous Improvement Engineer

  • Implemented Process management/Process improvement techniques following Lean Six Sigma principles.• Spearheaded flow Kaizen event achieving 10% productivity improvement~$150,000 annualized savings.• Created staffing requirements chart based on production mix and time study to meet the takt time. • Implemented heijunka board to level load production.• Achieved 80% reduction in manufacturing lead time by implementing one-piece flow. • Established safety stock levels and re-ordering points for raw material reducing part shortage by 28%.• Created new self-sustaining processes that included identifying and tracking the appropriate KPI’s to meet stake holder expectations.• Assisted in teaching Lean Six Sigma principles to line staff; trained others in use of tools and methodologies as part of project execution. • Led development and deployment of programs that created a culture of waste elimination, improved cycle time, reduced variation, eliminated defects and improved compliance by directly providing hands on leadership of key projects and teams for continuous improvement.• Implemented Daily Management and Gemba walks across all facilities to optimize savings and create a problem solving culture throughout the enterprise.• Facilitated cross-functional teams to achieve Kaizen objectives.• Worked with Lean Champions to ensure adequate resources, support and consultation to realize key projects in accordance with corporate strategy. Show less

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  DHL Express

  Jun 2021 - Mar 2022

  First Choice Analyst (Continuous Improvement)

  -Trained 100+ employees in 5S+Safety, Eliminating Waste & FMEA concepts.-Led the preparation for CII National 5S Excellence certification audit.-Point person for 6S certification of facilities PAN India.-Facilitated DMAIC initiatives-ensuring proper methodology is followed to improve efficiency & customer satisfaction.-Liaised with global & regional teams to develop, implement & manage India’s CI initiatives.

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  Caterpillar Inc.

  Mar 2022 - now

  CPI Black Belt Engineer