Awais Khan

Applied engineering methodology and problem-solving skills to optimize technical operations, maintaining analytical and process improvement capabilities.

• Led process improvement initiatives using lean principles (5S, Kaizen), reducing manual processing time by 35% and improving workflow efficiency across operations

• Conducted root cause analysis on system failures and process bottlenecks using 8D methodology, implementing corrective and preventive actions that reduced recurring issues by 40%

• Developed automated data validation tools using Excel VBA and Power BI dashboards, eliminating manual errors and reducing reporting time by 60%

• Created and maintained technical documentation including SOPs, process flow diagrams, and training materials, ensuring standardization and knowledge transfer

• Performed validation activities for new process implementations, ensuring functionality and compliance requirements were met before rollout

• Trained and mentored 5+ technical specialists through structured onboarding programs, developing training curricula and hands-on workshops

• Conducted process audits to evaluate compliance, identify gaps, and implement continuous improvement measures

• Contributed to mechanical system design and simulation-based optimization using engineering software

• Monitored and analyzed operational data (flow rates, pressure, temperature) to support equipment reliability and field performance optimization

• Investigated equipment malfunctions, determined root causes, implemented corrective actions, and updated maintenance records

• Developed field-level technical reports and supported process validation activities for production equipment

• Designed and validated pneumatic-hydraulic cabin tilt mechanism using SolidWorks and ANSYS FEA, ensuring structural integrity under 2,500 kg load conditions with appropriate safety factors and compliance with industry standards

Led design and validation of cabin tilt mechanism for commercial truck assembly line, demonstrating full engineering project lifecycle from concept through implementation.

• Conducted ergonomic assessment and time-motion studies on assembly line, identifying inefficiencies that reduced operator strain, improved cycle time by 18%, and eliminated motion waste

• Developed engineering documentation including assembly drawings, BOM, process flow diagrams, SOPs, and PFMEA, facilitating clear communication of design intent and manufacturing processes

• Collaborated with assembly technicians and production supervisors to optimize tooling layout and operator workflow, applying 5S principles to enhance workstation organization and standardization

• Applied Industry 4.0 technologies (AR/VR visualization) for immersive design reviews and interactive assembly sequence validation with cross-functional stakeholders

• Coordinated with suppliers for component sourcing, performed cost-benefit analysis, and prepared cost estimates for tooling fabrication and implementation, ensuring alignment with project budgets and timelines

Acquired foundational knowledge of high-volume precision machining and manufacturing operations within the defense industry.

• Observed diverse manufacturing processes including forging, casting, CNC machining, stamping, heat treatment, surface finishing, and final assembly operations

• Observed assembly line balancing techniques, workflow optimization strategies, and just-in-time (JIT) production systems

• Gained understanding of ISO 9001-compliant quality management systems, inspection protocols, and safety standards in high-volume high-volume production environment

• Witnessed material testing and inspection methods: non-destructive testing (NDT), hardness testing, tensile strength evaluation, and dimensional inspection