Asish Mathew
Oshawa,Canada
Summary
Results-driven Project Execution Engineering Lead specializing in material delivery automation, managing 15+ projects at GM Oshawa General Assembly with $6M+ in annual savings. Successfully deployed 49 AMRs and 18 chargers in 2024, achieving a 36 HC reduction and $3.6M in savings. Recognized five times in 2024 for early project launches with zero production downtime.
Skilled in Industry 4.0 technologies, AMR implementation with top suppliers, and delivering GMNA’s first conveyor-intersecting AMR solution. Expertise in end-to-end project management, vendor coordination, ROI analysis, and capital budget oversight. Mentor to four engineers and a proven leader in cross-functional collaboration and process improvement.
Overview
7
7
years of professional experience
Work History
Project Execution Engineering Lead – Material Delivery Automation
General Motors
09.2023 - Current
- Project Manager for all material delivery automation projects across GM General Assembly at Oshawa campus
- Currently handling more than 15+ automation projects leading to an equivalent saving of $6 million in savings
- Deployed a total of 6 projects – 49 Seegrid AMRs and 18 chargers resulting in a total of 36 HC reduction and $3.6 million saving just this year
- Got recognized 5 times just this year for launching projects before the deadline and with Zero production downtime
- Deploying Industry 4.0 Autonomous Mobile Robots (AMR) for material delivery without or minimal human engagements
- Have worked with almost all of the AMR suppliers so far such as Seegrid, JBT, Vecna, OTTO, KUKA and have successfully launched multiple projects with them
- Successfully did the first project in entire GMNA where an AMR can communicate & cross a conveyor transfer intersection
- Currently responsible to all the steps involved in the project from scope generation, design, getting plant/union buyoff, layout generation, install, launch and CI after hand over
- Responsible for conducting tech reviews between multiple vendors, generate RFQ, SOR, ROI, PO and also the maintenance package
- Coordinating with plant GSC/ME/IE/IT/Safety/AMR Vendors to remove any roadblocks for timely deployments
- Currently mentoring a total of 4 direct reports – 2 Industrial Engineers and 2 project engineering on various IE and Project management concepts to ensure success
- Conducting business case analysis & executing modern technologies safely where payback is less than two years
- Estimating budget requirements for capital purchase, ensuring approvals, purchase order release & timely delivery
- Tracking AMRs in each plant, coordinating with plant team for intra plant asset transfers, as necessary
- Ensuring 62 lessons learned readiness scorecard items are in green status before each AMRs go-live
Senior Industrial Engineer
General Motors
08.2021 - 09.2023
- Working as a Direct Labour Industrial Engineer in General Assembly looking after current & future models
- Successfully led a head reduction plan in the IP line and eliminated 12 heads equivalent to $1 Million+ overall savings
- Lead an organization-wide Continuous Improvement Process training class and trained more than 100+ salaried staff
- Successfully executed an NVA reduction campaign and was able to bring down nonvalue-added work by more than 20%
- Currently took over responsibility for Cockpit and Box /VAC line for current and future products
- Successfully lead the launch Industrial Engineering activities for MY24 T1 trucks in Final assembly lines
- Successfully lead the IE activities for launch of the Chevy Silverado 1500 LD Light Duty version on the Box line and 2 Final assembly lines
- Lead the IE activities for launch on Chevy Silverado 2500HD, and 3500HD in Box line Final assembly lines, including more than 140 workstations
- Got recognized in front of the entire staff for showing ‘ON ME’ GM behavior in multiple areas
- Drive development and/or installation of direct and indirect labor standards and methods
- Track labor, efficient manpower utilization, and line balancing
- Conduct Job Ergonomics evaluations
- Analyze problem process constraints and conduct equipment cycle time analysis
- Recommend the most efficient distribution of manpower and review daily employee manpower, analyze plant methods and standards
- Review and propose changes in plant layout, processes, material handling, routing, etc
- Analyze production and non-production operations to determine those requiring study and develop new or improved methods
- Coordinate engineering changes and planning
- Conduct value stream mapping and process audits
- Develop cost-saving project proposals and lead projects
- Interface with Production Supervision and Unifor Local union to settle job disputes
- Assist production in planning labor allocations for mix and line speed changes
Sr. Industrial Engineer -Operations
Collins Aerospace Systems
01.2020 - 08.2021
- Lead a project and simulated the process flow in the facility to identify the Wait/Queue time in between processes and reduced it up to 6% by line balancing techniques
- Lead a project to eliminate the setup time involved in different process and reduced it by 23%
- Performing process simulations to identify bottlenecks in the process using Simul8 and doing line balancing techniques to eliminate the bottlenecks
- Working with operations to develop and lead continuous process improvements to eliminate wastes in the process
- Created an in-depth process map and Value Stream Map (VSM) of plant operations and classified each process into VA, SVA, NVA for future continuous improvement activities
- Monitored key performance indicators (KPI's) e.g
- Machine efficiency, direct labor productivity etc
- Developing plant floor layouts, process documentation, operator instructions & Best Practices
- Generating, analyzing and presenting various reports on Quality, Productivity, Queue time & On-time delivery
- Implemented 5S in various workstations
Industrial Engineer
FibreCast Inc
10.2017 - 01.2020
- Optimized the process flow of the facility using Lean Manufacturing principles and increased the productivity by 18%
- Lead an On-time delivery service improvement project
- Successfully increased on-time delivery from 82% to 95% by conduction root cause analysis study
- Lead planning and execution of work orders daily and made sure that it is being done most cost-effectively
- Calculating and reviewing manpower requirements in various processes according to production plans
- Leading a team of supervisors and hourly associates (150+) operating across multiple shifts towards operational excellence
- Study and execute strategic planning and forecasting to determine the staffing need and shift requirement
- Conducting routine review and evaluation of supervisors and hourly associates for the appraisal process
- Conducting interviews to hire both salaried and hourly employees according to production demand
- Automated several reports resulting up to a 95%-time reduction
- Project leader in implementing cellular manufacturing model in the facility
Education
Master of Engineering - Industrial Engineering-Coop
University of Windsor
Windsor, ON08.2018
Skills
- Project Management PMI
- Automated material handling system design
- AutoCAD
- Mobile robotics AMRs
- Technical documentation and Standards
- Analytical Modeling
- Material flow strategies
- Lean Manufacturing
- Process improvement
- Budget management
- Problem-solving abilities
Timeline
Project Execution Engineering Lead – Material Delivery Automation
General Motors
09.2023 - Current
Senior Industrial Engineer
General Motors
08.2021 - 09.2023
Sr. Industrial Engineer -Operations
Collins Aerospace Systems
01.2020 - 08.2021
Industrial Engineer
FibreCast Inc
10.2017 - 01.2020
Master of Engineering - Industrial Engineering-Coop
University of Windsor