Highlights
• Award winning employee & student
• Close to 3 years of Industrial Engineering experience
• Extensive capacity modeling via time studies
• Well-versed with Lean Methodologies
• Established 5S program for SolarWorld Module Factory
• Good project management skills
• Excellent communication skills
• Prolific leadership skills
• Outstanding people skills
• Knowledge driven
• Performance oriented
Work Experience
SolarWorld Industries America Inc. (Sep 2010-Present)
Industrial Engineer
Capacity Modeling
• Created and updated capacity models for over 50 High Volume Manufacturing (HVM) toolsets, development toolsets and automation cells in 4 factories namely Crystal Growing, Wafering, Cell and Module.
• Played a key role in Final Acceptance Testing (FAT) of the Module Factory automation line contributing to savings of $1.35 million –
o Manually validated the cycle times and SEMI E-10 equipment states being reported by the 26 toolsets undergoing FAT to the Manufacturing Execution System (MES)
o Monitored cycle times, uptimes, availability, and utilization for 26 toolsets on a daily basis assessing whether or not the production line was meeting the contracted goals
o Trained all engineering and production staff on SEMI E-10 standards
• Created capacity models demonstrating future capacities in lieu of strategic changes to toolsets and automation lines
o Half-Cell Module – Developed a capacity model for the stringer tool to simulate half-cell production. Demonstrated to management that speed upgrade to the tune of $100,000 on the stringer tool was not required, as established production targets for both normal and half-cell modules could be met with the current configurations.
o 72-Cell Module – Performed extensive analysis on factory capacity in lieu of introduction of 72-Cell modules. Provided management with information related to changes in cycle times and throughputs of affected toolsets and the overall factory constraint.
o Chemical Vapor Deposition(CVD) toolset – Co-developed a capacity model for the CVD toolset. Analysis helped determine the number of cleaning and drying tools required to be purchased in lieu of its operations.
• Created a complex capacity model for shipping. Model considered multiple variables such as number and type of shipments, number of operators available, and type of shipping tasks performed. Model established shipping capacity and was used to determine if shipping staff was overloaded. In the event of an overload, the model determined amount of overtime or extra shipping operators needed to prevent the overload. Model is used by logistics personnel on a daily basis to understand shipping capacity given various shipping situations.
Lean Manufacturing
• Developed a Kanban system for Just-In-Time (JIT) deliveries of 22 major consumables for the Module factory floor with an estimated 43.91% decrease in floor inventory.
• Developed and implemented a transportation system involving special carts and trays for the purpose of moving fragile solar cells between tools and rework stations minimizing breakage and improving ergonomics. Cost savings of the implemented solution is around $7,300/year.
• Implemented a better Preventative Maintenance (PM) procedure for the Stringer tool solder heads resulting in cost savings of $8,800/year.
• Incorporated a two person PM procedure for Stringers tools cutting the PM time from 52.5 min to 30 min. Estimated increase in production was 197 laminates/day.
• Developed a solution for transporting heavy ribbon spools from point of storage to point of use. Implemented solution reduced lifting and carrying of heavy spools by operators, bypassed possible use of staircase, and reduced the number of operators required from two to one.
• Used Value Stream Mapping to improve wire saw turn operations in Wafering factory. Recommended two operator turn operations reducing turnaround times by 28 min.
• Developed and helped implement an intermediate material pull system incorporating visual cues for the reorder of consumables used in the Module factory in the absence of night shift deliveries.
• Performed workflow analysis to improve Sunkit Assembly Operations through reduction and better organization of Sunkit assembly parts, reduction of travel distances, and increasing safety during the assembly process.
• Developed and implemented a transportation solution for safer and efficient return of fixtures from the point of removal to the point of use. Implemented solution resulted in decreased time and distance travelled, while increasing safety of the collection process.
5S
• Developed training material for Module Factory 5S program
• Trained over 100 Module Factory employees on 5S on 4 shifts
• Set up 5S structure, project management, policies and strategies
• Set up 5S audits and management walks
• 5S Project Management
o Lead 4 teams of production techs from all 4 shifts
o Provided facilitation, direction and mentorship in 5S projects
o Allocated responsibilities an set up deadlines for 5S project work
SolarWorld Industries America Inc. (Mar 2010-Sep 2010)
Industrial Engineering Intern
• Performed time studies and developed capacity models on Wire-Saw operations in Wafering
• Played a key rol...
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