OSMAN DEMIR
Bala Cynwyd,USA
Summary
Six Sigma / Lean Manufacturing / Continuous Improvement / Process Design & Improvement / Project Management / Engineering
Six Sigma Green Belt offering over 15+ years of experience in quality engineering, welding engineering, lean manufacturing, product/process design and project management. Deliver quality controls and enhancements to proactively address problems and improve product quality, manufacturing flow, customer satisfaction and bottom-line results.
Overview
21
21
years of professional experience
1
1
Certification
Work History
Senior Product Engineer
MILTON ROY/INGERSOLL RAND
01.2020 - 01.2021
- Promoted to sustain engineering specifications, drawings, BOMs, product agency approvals and support production, quality and supply chain with all engineering activities such as troubleshooting complex pump failures, root cause investigation, new supplier/product approvals
- Maintained product configuration and engineering BOMs
- Supported supply chain for purchasing equivalency/substitution, deviation requests
- Facilitated root cause investigation for customer complaints, troubleshooting of pump failures
- Managed production router maintenance and update, drawing or Bill of Materials Errors, engineering specifications, production work instructions
- Managed all regulatory compliance activities for UL, INTERTEK and NSF for multiple different products
Product Compliance Engineer
MILTON ROY/INGERSOLL RAND
01.2020 - 01.2021
- Promoted to manage all regulatory compliance activities for various products and support production with sustaining existing product lines
- Improved designs of various products to address customer issues
- Managed all regulatory compliance activities for UL, INTERTEK and NSF for various product lines
- Conducted regulatory product audits and assisted UL, INTERTEK and NSF regulatory audits
- Managed product support jobs and delegated among other engineers
- Supported R&D with the new product development; conducted production and life tests
- Supported supply chain to identify new sources and any product specification changes
- Designed and built new test stands for various pressure to test pumps for pressure and flow
Continuous Improvement Engineer
MILTON ROY/INGERSOLL RAND
01.2019 - 01.2020
- Promoted to improve and streamline assembly process for various product lines, eliminate waste, improve efficiency, on time delivery and quality
- Identified improvement opportunities for design engineering to simplify the product and assembly process
- Developed process flow maps to streamline assembly processes
- Created assembly work instructions to standardize many different pump assemblies
- Analyzed data to identify improvement opportunities for production lines
- Developed and executed DOE’s to improve FPY (first pass yield) of certain product line
- Performed many FTA’s for many different root cause investigation projects
- Performed time cycle value analysis and value stream mapping
- Facilitated various Kaizen events to improve production efficiency and minimize waste and created FMEA for assembly processes
Senior Supplier Quality Engineer
MILTON ROY/INGERSOLL RAND
01.2016 - 01.2019
- Hired to manage all quality activities related to supplier quality and support production with all plant quality activities
- Managed PPAP process for many different product lines including injection molding, casting, machining and electronics
- Managed all supplier and related quality activities and SCAR (supplier corrective action report) process
- Supported production with day to day quality activities and managed MRB process
- Performed internal audits and supported ISO 9001:2015 certification audit
- Supported supply chain with all cost saving initiatives and saved $2M in 2017 by diversifying supply chain base
- Performed supplier qualification audits and periodic ISO quality system audits
- Managed/executed various Kaizen events related to assembly line and shipping process
- Worked with R&D team to launch two new product lines, managed all FAI process for the new parts
- Worked with many different suppliers operate in electronics, injection molding, machining, casting and welding industries
- Managed 8D process and all customer complaints and developed FMEA for the new product line launched
Quality Engineer
MITSUBISHI ELECTRIC
01.2015 - 01.2016
- Hired to manage day-to-day quality activities on production floor and manage supplier quality
- Managed ISO-9001:2000 internal audit process and assisted external audits
- Worked with interdepartmental team to manage day-to-day quality activities
- Conducted daily meetings to manage non-conforming products on production floor
- Done RCA (Root Cause Analysis) to resolve quality issues on the production floor and at suppliers
- Managed CAPA process to correct quality issues
- Developed and manages various supplier bases for power transformers
- Performed supplier audits based on ISO 9001:2000 quality assurance systems
- Trained production personnel on blue print reading
- Done capability studies for different production lines and suppliers
- Used SPC and different quality tools to improve product quality
- Developed and certified new WPS (Welding Procedure Specification)
- Reduced cost of transformer tanks up to 50% by developing new suppliers and educed supplier quality defect by 40%
Quality Manager
GAMESA WIND US
01.2009 - 01.2014
- Promoted to provide support in all quality activities from raw material to finished product including steel plates, flanges, internals and manufacturing of wind towers
- Helped managing daily quality activities including weld UT inspection, paint inspection, visual and dimensional inspection of wind towers by coordinating 7+ quality inspectors at various job sites
- Liaised between customer and supplier and established information flow process to manage customer complaints
- Implemented a change control process for design changes and created database for document and change control to aid the project management department
- Developed and maintained FMEA (Failure Mode Effect Analysis) for wind tower manufacturing process
- Participated actively in various cost reduction projects by redesigning wind towers in cooperation with engineering and purchasing
- Developed and managed APQP and PPAP for various wind tower suppliers for wind tower manufacturing projects
- Incorporated Six Sigma/Lean methodology to redefine NCR process to reduce the waste in the process
- Developed supplier-qualification program that minimize the risk for wind tower manufacturing projects
- Incorporated Six Sigma methodologies to solve a range of design and manufacturing problems, this includes 8D Root Cause Analysis methodology and 5S
- Liaised between design and manufacturing team as a contributor to development of various tower designs such as G5X, G8X 100m G9X 90 m
- Ensured product manufacturability, robust design, compliance with regulatory requirements and transition from prototype to production
- Developed WPS (Welding Procedure Specification) qualification according to ISO 15614-1 standard for US supplier base
- Performed over 10+ Supplier Audits including technical audit and process audits
Project Engineer
GAMESA WIND US
01.2008 - 01.2009
- Promoted to provide project management, technical direction and design-build leadership on wind tower projects for a wind turbine manufacturer
- Heavily involved in business development with US supplier base, with proposals and presentations cited as key to large contract on wind tower projects ranging from $1M to $40M
- Managed all three aspects (cost, quality and schedule) of various projects of wind tower production starting from raw material to finished product
- Established tracking metrics with subcontractors and implemented corrective and preventive actions to minimize the impact on delivery schedule of the projects
- Tracked raw material status for 4+ subcontractors and coordinated with procurement team on delivery of raw materials to keep production pace vs
- Schedule
- Worked with purchasing department to obtain the best possible purchase of the raw materials for wind tower manufacturing
- Negotiated change orders with suppliers for engineering design changes throughout the project
- Analyzed actual contracts looking for improvement clauses
Acting Quality Manager
GAMESA WIND US
01.2007 - 01.2008
- Promoted to manage all quality activities for wind tower production, improve the efficiency of production operations, manage the engineering change process and act as customer liaison for product quality issues, train welders on various welding processes
- Implemented ISO-9001:2000-quality assurance system, led ISO recertification effort, have been through three internal and one external ISO audit
- Conducted process mapping and time/capability studies to improve throughput by 25%, eliminate bottlenecks and ensure adherence to product specifications
- Utilized Cause &Effect/ Fishbone Diagram for Root Cause Analysis of the chronic/repeated welding and paint defects
- Prepared process flow charts for each workstation to simplify the work instructions for operators/ to increase the efficiency
- Prepared training programs for production supervisors about ISO-9001:2000 and trained them on procedures and work instructions
- Developed internal training programs for Quality Inspectors on Sub-Arc, MIG Welding methods-related weld defects and paint applications-related paint defects
- Certified Quality Inspectors in cooperation with a third party entity according to ASNT SNTC 1-A
- Certified welders according to EN 287-4 welder qualification standard in cooperation with Materials & Process Engineering
- Developed software to improve the tracking of inspection and document control process
- Hired professionals for different positions such as Quality Engineer, Documentation Engineer and Quality Inspector
- Worked with warehouse staff to implement ISO-9001:2000 procedures for warehouse and trained all warehouse staff on ISO and internal ISO-9001:2000 procedures
Quality/ Process Engineer
GAMESA WIND US
01.2006 - 01.2007
- Hired to develop inspection team and oversee 8+ NDT inspectors
- Implemented and refined manufacturing processes by applying continuous improvement and lean manufacturing principles to all areas of production
- Supervised 8+ inspectors and organized the inspection process
- Supervised production about weld defects and trouble shootings for submerged arc welding process
- Reduced weld defects from 35% down to 4% by implementing 8D problem solving methodology
- Applied (PWHT) heat treatment to the steel to reduce the residual stress in the metal after SAW welding
- Developed internal training programs for welders on the SAW and MIG welding methods, application, defects and trouble shootings
- Organized hands-on training program about MIG welding methods for welders in cooperation with WTTI Welding Institute
- Incorporated Lean process with warehouse to reduce the waste in the process of delivery of raw materials to production
- Prepared testing plan according to EN and AWS standards for conducting welder qualification tests
- Developed inspection procedure for ultrasonic inspection of weld in cooperation with UT Level III
- Enhanced management experience and decision making under time pressure and stressful work environment
NDT Engineer
S&Q MART Quality Assurance Inc. Testing& Inspection Division
01.2002 - 01.2003
- Projected third party inspection services on behalf of Novartis, Enron, Georgia Pacific, and BP
- Performed in-service inspection of HRSGs (Heat Recovery Steam Generator system), pressure vessels, storage tanks, boilers, heat exchangers, pipelines, steel constructions, and similar industrial components for clients in energy, and manufacturing industries
- Developed heat treatment procedures and performed heat treatment to tubing of the HRSG for post-weld repair during the in-service inspection of gas turbines
- Developed welding procedure (WPS) for Titanium alloys and performed the procedure on heat exchanger used in gas turbines
- Performed Hydrostatic tests for the longitudinal seam of the pipes manufactured by Resistance Welding
- Performed following NDT tests; on-site metallographic examination (Replica), PT, MT (daylight and florescent), UT, and radiographic film evaluation for clients in energy, petro-chemical, chemical, paper, metal, piping industries
- Prepared test procedures for each different application
- Supervised NDT technicians to conduct projects
- Conducted following material tests; metallographic, tensile, bend, hardness, and charpy for clients in metal, piping, and energy industries
- Prepared test procedure for conducting the tests according to ASME, AWS, and EN standards
- Developed paint application procedure and supervised on site paint application process according to EN/ISO 8501-1 and 12944
Intern
The Scientific and Technical Research Council of Turkey (Marmara Research Center)
01.2000 - 01.2001
- Assisted research technicians in NDT lab to perform NDT tests for following clients GE, Cimtas, Mannesman
- Assisted research engineers to conduct projects in SEM/TEM, and Metallography lab for following clients GE, Ford
- Responsibilities included conducting and reporting test results to research engineer
Education
Six Sigma Green Belt -
Drexel University
Philadelphia, USA07.2010
Project Management -
Penn State University
Philadelphia, USA08.2009
Master of Science - Material Science & Engineering, Nano-materials & Nanotechnology
New Jersey Institute of Technology
Newark, USA05.2006
Bachelor of Science - Material Science & Engineering Technology, Welding Engineering Technology
Marmara University
Istanbul, Turkey06.2002
Skills
- Six Sigma
- ISO Leadership
- Lean Manufacturing
- Service Operations
- Lean Quality Tools
- FMEA
- Control Plans
- Pareto Charts
- Fishbone Diagrams
- Six Sigma 5S
- 8D Methodology
- Geometric Dimensioning & Tolerancing (GD&T)
- Welding Engineering
- Welding Metallurgy
- Welding Process & Techniques
- SAW
- TIG
- MIG
- MAG
- SMAW
- Codes & Specifications
- AWS
- ASME
- API
- Process Development
- Process Improvement
- Waste Reduction
- Output Increase
- Statistical Process Controls (SPC)
- Quality Auditing
- Technical Auditing
- Weld Inspection
- NDT
- Ultrasonic
- Radiography
- Magnetic Particle
- Liquid Penetrant
- Visual Inspection
- Corrosion Protection
- Paint Application
- Paint Inspection
- Wind Turbine Manufacturing
- Wind Tower Manufacturing
Certification
- NDT Ultrasonic Testing Level 1, MRC (Marmara Research Center), Gebze, Turkey
- NDT Radiographic Testing Level 1, Level 2, MRC (Marmara Research Center), Gebze, Turkey
- NDT Magnetic Particle Testing Level 2, S&Q MART Inc., Istanbul, Turkey
- NDT Liquid Penetrant Testing Level 2, S&Q MART Inc., Istanbul, Turkey
- Six Sigma Green Belt, Drexel University, Philadelphia, PA
- Project Management, Penn State University, Philadelphia, PA
- CWI (Certified Weld Inspector), AWS, Memphis, TN
Personal Information
Citizenship: U.S. Citizen
Publications
Effects of heat treatment conditions on mechanical properties of 17-4 PH Stainless Steel, S.Salman, H.O.Gulsoy, O.Demir, 9th Denizli Materials Symposium, 2002, Denizli, Turkey
Training
- 8D Problem Solving Methodology, DVIRC (Delaware Valley Industrial Resource Center), Philadelphia, PA
- Leadership Skills-Conflict Management, Buck County College, Philadelphia, PA
- ISO 9001:2000 training, Gamesa Internal ISO Team, Philadelphia, PA
- Project Management Fundamentals, Bucks County College, Philadelphia, PA
- Advance Excel Training, Bucks County College, Philadelphia, PA
- NDT Visual Testing Level II Training, GE Inspection Technologies, Philadelphia, PA
- Paint Application and Inspection Methods, Hempel Academy, Philadelphia, PA
- Welding Seminar by AWS, Memphis, Memphis, TN
Timeline
Senior Product Engineer
MILTON ROY/INGERSOLL RAND
01.2020 - 01.2021
Product Compliance Engineer
MILTON ROY/INGERSOLL RAND
01.2020 - 01.2021
Continuous Improvement Engineer
MILTON ROY/INGERSOLL RAND
01.2019 - 01.2020
Senior Supplier Quality Engineer
MILTON ROY/INGERSOLL RAND
01.2016 - 01.2019
Quality Engineer
MITSUBISHI ELECTRIC
01.2015 - 01.2016
Quality Manager
GAMESA WIND US
01.2009 - 01.2014
Project Engineer
GAMESA WIND US
01.2008 - 01.2009
Acting Quality Manager
GAMESA WIND US
01.2007 - 01.2008
Quality/ Process Engineer
GAMESA WIND US
01.2006 - 01.2007
NDT Engineer
S&Q MART Quality Assurance Inc. Testing& Inspection Division
01.2002 - 01.2003
Intern
The Scientific and Technical Research Council of Turkey (Marmara Research Center)
01.2000 - 01.2001
Project Management -
Penn State University
Master of Science - Material Science & Engineering, Nano-materials & Nanotechnology
New Jersey Institute of Technology
Bachelor of Science - Material Science & Engineering Technology, Welding Engineering Technology
Marmara University
Six Sigma Green Belt -
Drexel University
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