Khaled Almahshi
Birmingham,AL
Summary
Dynamic Lean Six Sigma Engineer with 10+ years of experience in improving efficiency & reducing costs. Passionate and detail-oriented leader with a proven track record of exceeding targets through strategic metrics. Certified Lean Six Sigma Black Belt (CSSBB), skilled in DMAIC tools such as 5S, Kaizen, Value Stream Mapping, and VOC. Proficient in advanced statistical analysis, including DOE, GR&R, and Process Capability. Utilizes a disciplined, data driven Six Sigma approach to eliminate defects. Effective communicator and team player, adept at coordinating with management, vendors, and staff to achieve goals.
Overview
13
13
years of professional experience
1
1
Certification
Work History
Sr Industrial Engineer
Blue Origin
09.2023 - Current
- Company Overview: Aerospace
- Support Blue origin's Tube Shop and BE-7 Program, Lead Value stream mapping and enhance process efficiency through CT reduction and process improvement
- Optimized production processes by conducting thorough time studies and implementing effective workflow improvements.
- Conducted detailed capacity analysis studies to support informed decision-making on capital investments and expansion plans.
- Established Batching strategy that helped in reducing process CT and enhance efficiency by 70%
- Managed capital expenditure projects from initial scoping through completion, ensuring on-time delivery within budget constraints.
- Act as a core member in BE-7 team who stood up the new engine plant in Huntsville
- Support production related activities resulting in the build of first BE-7 engine in Huntsville in less than a year
- Led cross-functional teams to design and implement process improvement projects that resulted in increased throughput and reduced lead times.
- Evaluated new equipment and technology options, making strategic recommendations that led to increased capacity and reduced downtime.
- Mentored junior engineers on best practices in industrial engineering methodologies, fostering a culture of knowledge sharing within the team.
- Applied value stream mapping techniques to assess current state processes and develop future state plans aligning with organizational objectives.
- Layout Reviews and Optimization
Quality Engineer, Chassis and Vehicle Dynamics
Mazda Toyota Manufacturing (MTM)
12.2022 - 09.2023
- Company Overview: Automotive
- Responsible to define, contain, root cause, and eliminate Quality and Throughput issues identified within the assembly plant for the Toyota corolla cross production line
- Monitor compliance to Process Control Plans & Tool and strive for processes that are stable, in control, and centered
- Act as subject matter expert for all Alignment related issues (Toe, Camber, Caster)
- Troubleshoot and investigate Alignment related activity resulting is reducing out of alignment veh by at least 30%
- Analyze warranty data to identify any problems/trends and initiate investigations to root cause and resolve the issues
- Work closely with suppliers on evaluating new parts and provide technical suggestions to reduce risk introduced to production lines
- Work with launch team on new veh builds
- Review non-conformance parts and sub-assemblies for initial disposition and root cause analysis
- Performed quality inspections and drafted reports to detail non-conforming material issues.
- Implemented process improvements based on Lean Six Sigma methodologies, resulting in reduced waste and increased efficiency.
- Enhanced product quality by implementing rigorous inspection procedures and conducting thorough root cause analysis.
- Improved supplier reliability with thorough assessment and feedback mechanisms, fostering stronger partnerships.
Sr Quality Engineer, Chassis and Vehicle Dynamics
Rivian Automotive
09.2021 - 12.2022
- Company Overview: Automotive
- Lead and support chassis product development efforts at the plant aiming to upgrade and improve process to meet ramp up efforts and support process improvement and continuous improvement activities between R&D and factory
- Work closely with Manufacturing to contain and resolve production issues related to Chassis and Vehicle Dynamics
- Evaluate braking, steering, alignment, ride, and handling attributes in production vehicles both subjectively and objectively
- Help in designing and running trials (DOE) at the plant to assess new products/features and their feasibility/implementation on the lines
- Work with cross-functional teams on troubleshooting failure modes and developing countermeasures
- Drove standardization efforts across multiple production lines to ensure consistent product output meeting stringent specifications.
- Led Six Sigma projects resulting in cost savings through improved process capabilities and waste reduction strategies.
- Conducted regular audits of suppliers and vendors to maintain high-quality supply chain management.
Staff Chemical Process Engineer, Friction Material
Akebono Brake Corporation
02.2021 - 09.2021
- Company Overview: Automotive
- Lead / Responsible Engineer for continuous improvement initiatives using Lean Six Sigma methodologies, resulting in significant process enhancements.
- Leading 6-sigma project to increase process output by improving performance component of the OEE by 15-20%
- Leading 6-sigma project aiming to improve process output by reducing un-planned downtime and improve availability component of the OEE by 10-20%
- Deliver training and coaching sessions to various engineers/team members to encourage usage of 6-sigma tools and DMAIC methodology
- Provided expert troubleshooting support during critical plant issues, quickly resolving incidents while minimizing production losses.
- Increased product yield by implementing improved processes.
- Improved product quality by conducting root cause analysis on process deviations and implementing corrective actions.
Senior Chemical Process Engineer, Friction Material
Akebono Brake Corporation
09.2019 - 02.2021
- Company Overview: Automotive
- Responsible for implementing newly developed R&D products/process at the plant and drive quality improvement
- Develop Statistical Process Control Methodology to improve quality at Manufacturing Plant
- Performing DOE's at plant for process improvement
- Enhanced product performance by optimizing design parameters and conducting thorough testing procedures.
- Reviewed technical documentation to ensure accuracy and compliance with industry standards before submission to regulatory agencies or clients.
- Developed innovative solutions for complex engineering problems, resulting in improved product quality and reduced manufacturing costs.
- Created detailed reports on engineering activities and findings.
- Documented and developed engineering procedures and processes.
Chemical Process Engineer, Friction Materials
Akebono Brake Corporation
07.2016 - 09.2019
- Company Overview: Automotive
- Participate in product development activities and plant improvement through Designing of Experiment and root cause analysis
- Determine optimized process conditions for making friction material
- Investigate seasonal effect of friction material on brake pads performance, which helps in satisfying customer requirements and reduce scrap/ non quality cost
- Researched and developed novel manufacturing processes to reduce production time.
- Conducted technical feasibility studies for the introduction of new product lines, ensuring a smooth transition from development to production phases.
- Played a key role in the successful scaling up of pilot projects into full-scale production plants, meeting project timelines and budget constraints.
Graduate Student Research Assistant
Ford Motor Company/University of Michigan
06.2014 - 07.2016
- Company Overview: Automotive
- Worked for U of M on an alliance project with Ford Motor Company on a research project aims to reduce manufacturing cost of F-150 trucks, through achieving better understanding of Aluminum behavior at simulation stage
- Perform Finite element analysis (CAE) to Simulate mechanical the behavior of the material
- Performing a hybrid (numerical-experimental) calibration process to determine the fracture surface for the material
- Designing of experiment and implementation
- Interpreted and analyzed research data to draw conclusions on outcomes.
- Prepared fact sheets, tables, and graphs to summarize research results.
Quality Engineer
Nestle Waters
02.2012 - 01.2014
- Company Overview: Food & Beverage
- Worked for two years as a quality engineer responsible for maintaining all quality measures in place to insure consistent and reliable product flowing to the customers
- Develop DOE's and Troubleshooting Quality problems related to Injected Plastic Preforms
- Development of Quality management schemes 'QMS' to assure compliance with standards
- Supervising 10 technicians working on chemical and microbiological laboratories
- Deliver Coaching, Leadership Development and problem solving training sessions
- Improved customer satisfaction levels with timely resolution of non-conformance issues and effective
- corrective actions.
- Conducted regular compliance audits, ensuring adherence to industry regulations and standards.
Education
Master of Science - Industrial Engineering
University of Michigan
Dearborn, MI06-2016
Bachelor of Science - Chemical Engineering
Jordan University of Science And Technology
Amman, Jordan01-2012
Skills
§ Data Statistical Analysis
§ Minitab,JMP,SQL
§ AutoCAD,SolidWorks
§ Proficient in Design of Experiments
§ Six Sigma Black Belt Certification
§ NGMP
§ FMEA
§ CAE Simulation
§ Operational Capacity Analysis
§ Process Optimization
§ Process Mapping Expertise
§ Optimized Facility Layout
§ Quality control development
§ Manufacturing
§ Data Gathering
§ Process improvement
§ Data Interpretation
Certification
- Six Sigma Black Belt Certification
Languages
English
Full Professional
Arabic
Native or Bilingual
Timeline
Sr Industrial Engineer
Blue Origin
09.2023 - Current
Quality Engineer, Chassis and Vehicle Dynamics
Mazda Toyota Manufacturing (MTM)
12.2022 - 09.2023
Sr Quality Engineer, Chassis and Vehicle Dynamics
Rivian Automotive
09.2021 - 12.2022
Staff Chemical Process Engineer, Friction Material
Akebono Brake Corporation
02.2021 - 09.2021
Senior Chemical Process Engineer, Friction Material
Akebono Brake Corporation
09.2019 - 02.2021
Chemical Process Engineer, Friction Materials
Akebono Brake Corporation
07.2016 - 09.2019
Graduate Student Research Assistant
Ford Motor Company/University of Michigan
06.2014 - 07.2016
Quality Engineer
Nestle Waters
02.2012 - 01.2014
- Six Sigma Black Belt Certification
Master of Science - Industrial Engineering
University of Michigan
Bachelor of Science - Chemical Engineering
Jordan University of Science And Technology
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