Summary
Overview
Work History
Education
Skills
Timeline
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Faizan Malik

North Reading,Massachusetts

Summary

Ingenious Process Engineer tirelessly seeking mechanical process improvements and detecting process weaknesses. Dedicated to expanding throughput and reducing unnecessary project waste while pushing continuous improvement efforts. Focusing on Robotics Process Automation with hands on experience in Hardware Testing.

Overview

2
2
years of professional experience

Work History

Process Engineer Intern

Amazon Robotics
05.2023 - 09.2023
  • Authored, Standardized and Continuously Improved Assembly and Repair Instructions while making callouts for refining of processes in efforts to improve process workflow for the repair of 300+ Electro-Mechanical Robotic Systems
  • Standardized Retrofitting tools required in each step of the build/repair via Work Instructions
  • Kept track of Project documentation i.e., BOMs, Tools and Fasteners List, Part Numbers, Project Schedule, KPIs
  • Took ownership to write work instructions on an NPI Project, while keeping track of fasteners and tools by documenting and updating DFX Log, Fasteners and Tools Spreadsheets, streamlining the build process by 20%
  • Conducted training for technicians on an NPI process automation project while updating project documentation
  • Assisted the associates during build, i.e., providing required tools, fasteners, instructions, escalating DFX, DFA to QEs to insist on highest standards for best manufacturing practices, moving NPI to testing phase
  • Conducted Time Studies of Prototype Builds pertaining to the NPI build process for process documentation
  • Continuously Improved the process for the repair, upgrade, and deployment of 100+ mechatronic robotic systems by making Defect Docs, Escalating repair blockers i.e., missing inventory, delayed inventory, etc.

Electro-Mechanical Test Engineering Co-op (R&D)

Mercury Marine
01.2022 - 08.2022
  • Led Root Cause Analysis (RCA) and troubleshooting for over 100 failed electro-mechanical components while authoring
  • Technical Reports and performing quality inspections, to document findings and working cross departmentally to implement corrective actions. Reduced failed sensors by 30% over a 3-week period
  • Built 300+ wire harnesses consisting of sensors for engine components, leveraging electrical circuit design drawings
  • Successfully managed a Personalized FEA Modeling and Simulation project, from Project initiation to implementation and handover while meeting key project milestones and deliverables for the customer
  • Developed and executed test protocol to analyze Principal Stresses for failure analysis of an NPI product; operated Creo Parametric for the strain gauge analysis on tiller arm and bushing to analyze optimal strain gauge location for testing
  • Performed Finite Elements and Analysis (FEA) on tillers using Creo Parametric while leading engineering design review sessions to finalize strain gauge location
  • Successfully optimized process flow and timeline of a cross-disciplinary project by 50%. Project was standardized for future Interns and Co-Ops
  • Led execution of key functional tests (vibration, validation, product life cycle testing) 500+ Electro-Mechanical automotive components such as actuators, sensors etc, to obtain data for design and manufacturing improvements.

Rapid Prototype Intern

Technique Inc
06.2021 - 08.2021
  • Manufactured over 1000+ automotive components for Automotive Giants by operating stamping machines and plasma cutting gun for long shifts to meet customer’s deliverables
  • Successfully machined, deburred, stamped, and pressed on the manufacturing line in fabrication plant to meet Production Plan of Record (POR) i.e., over 1000 automotive components within 2 weeks
  • Authored and executed Quality Control test protocols for over 1000 metal components to meet quality demands leveraging Geometric, Dimensioning Tolerancing, and reading Technical CAD drawings for geometric precision.

Education

Bachelor of Science - Mechanical Engineering

Michigan State University
05.2023

Skills

  • Hard Skills: Asana, Test Engineering, Project Documentation, Work Instructions
  • MATLAB, Simulink, Python, Siemens NX, ANSYS, ALTAIR, Creo Parametric, Electro-Mechanical
  • Hardware Testing, Validation Testing, Time Studies, SolidWorks, Rapid Process Improvement
  • New Process Implementation
  • Technical Presentations
  • Continuous Improvements
  • Modeling and Simulation
  • KPI Monitoring
  • Testing Coordination
  • Equipment Optimization
  • Root Cause Analysis
  • Process Validation

Timeline

Process Engineer Intern

Amazon Robotics
05.2023 - 09.2023

Electro-Mechanical Test Engineering Co-op (R&D)

Mercury Marine
01.2022 - 08.2022

Rapid Prototype Intern

Technique Inc
06.2021 - 08.2021

Bachelor of Science - Mechanical Engineering

Michigan State University

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Faizan Malik