Summary
Overview
Work History
Education
Skills
Websites
Skills
Certification
Timeline
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PRASAD JOGLEKAR

Summary

Manufacturing Engineer with 2.5+ years of experience in development and commissioning of new assembly and functional test equipment for electronic fuel injectors which involve manufacturing processes such as fastening (torque and angle), press-fit, soldering, leak test, high-pressure testing, functional and hi-pot tests.

Overview

5
5
years of professional experience
1
1
Certification

Work History

Manufacturing Engineer

BorgWarner (Delphi Technologies - TMD)
04.2022 - Current
  • Led development of push fit press servo machine process and achieved direct saving of $1.5M. Developed height measurement system using Keyence GT2 sensors
  • Design test plans, test procedures and conduct validation activities for EUI Injectors using mechanical and software integration with cross sectional teams
  • Improved yield from 84.6% to 93.5% of high volume injector functional test by using Shainin problem solving method. Performed DOE studies to analyze return spring pre-load for different injector families actuator valves
  • Developed defect detection system using Cognex insight vision system. Designed HMI using Labview 2022
  • Improved Cycle Time by 9.45% automating injector torquing process. Designed HMI in C# and achieved data acquisition on SQL server
  • Develop and lead calibrations tests on pressure, flow, speed transducers, drive boxes and mechanical gauges
  • Improved air leak test performance by designing to tooling and conducting validation using pair-T statistical analysis
  • Design mechanical fixtures, air leak test & electrical test and functional test for injectors and its component
  • Develop and Debug vision system, laser system using various interfaces such as Keyence and Cognex
  • Actively working on feasibility study, development, validation & commissioning of a new automated test process for reusing of key injector component which generates an expected savings of $3M
  • Core technical member in preparing process documentation such as PFMEA, Control Plan, Process flow diagram, Engineering change request and Standard work instructions
  • Day to day tasks includes, data analysis, handling manufacturing engineering activities such as diagnosing FPY and process related issues for multiple EOL test machines and semi-automated assembly lines

Lean Engineer

BorgWarner (Delphi Technologies - TMD)
08.2021 - 04.2022
  • Implemented lean concepts to improve waste reduction, OEE, Cycle time (CT) to achieve material and information flow
  • Responsible for conducting data analysis for lean projects and perform thorough analysis from technical standpoint
  • Initiated and maintained project timelines for all the projects by working with cross functional teams
  • Created and updated standard cell documentation for production floor (JES, WCT, SOS)
  • Developed enterprise level value stream map to solve bottle necks and improve OEE.

Industrial Engineer

Spencer Butcher Group
06.2020 - 08.2021
  • Responsible for designing facility layout to ensure material flow using FIFO, KANBAN & JIT methodologies
  • Developed and deployed automated dashboard to monitor the equipment status board using C# and SQL
  • Lead team to design sequencing and bulk metering process with material flow standpoint for RAM TRX 2020
  • Created PFMEA, Control plans and Process flows for sequencing, metering process using APQP fundamentals
  • Managed standardization documentation in terms of DFM, JES, WCT, SOS, WI and 5S using Lean basics
  • Responsible to conduct time & motion studies using MOST to solve bottle necks and achieve process improvement
  • Successfully reduced CT of sequencing process by 19.33% re-designing the cell and using MOST for load balancing
  • Responsible to track PDCA involving engineering, supplier development, manufacturing, and logistic issues
  • Successfully achieved a reduction of $132,000 with operator head reduction and waste by redesigning the layout.

Lean Manufacturing Intern

BorgWarner (Delphi Technologies - TMD)
07.2019 - 05.2020
  • Assisted in layout design using Auto CAD & workflow analysis systems studies Cummins injector product line
  • Supported CI activities to achieve one-piece flow, reduce waste by 3.2%, improved changeover times by 12.6%
  • Helped in designing material replenishment routes to improved C/T by 16% and reduced quality defects by 6%.

Education

Master of Science in Industrial Engineering -

Wayne State University
05.2020

Bachelor of Engineering in Instrumentation Engineering -

University of Mumbai
05.2018

Skills

EXPERTISE : Process development,
Factory Acceptance Testing, Site
Acceptance Testing, Shainin problem
solving methodology, SQL, GD&T

CAD : SolidWorks 2020,

AutoCAD 2021

PROGARMING : SQL, LabVIEW 2023,
Excel VBA, Power BI

ANALYTICS : Minitab, Excel

OTHER SOFTWARES :
Microsoft Project
Cognex DataMan, Insight Explorer

Keyence vision system

HARWARE HANDLED :
Cognex Vision Systems
Keyence LVDT
IFM & Balluff Antenna, RFIA tags
IFM Inductive sensors

Skills

Minitab, SQL, MATLAB, C/C++/C#, Python, AutoCAD, Google Data Studio, LabVIEW, RsLogix5000, Cognex VIDI Suite, Solid works, MS Office, Visio, SAP, RT system, 8D, Red-X, DOE, Kaizen, Gage R&R, ISO/TS 16949, PMTS, SMED, SIMIO, 5S, ERP, TQM, APQP, DFSS, PPAP, SWOT, DMAIC, SIPOC, TPM, KANBAN, MODAPTS

Certification

  • Six Sigma Green Belt - May 2019
  • Shainin Problem Solving Methodology - Aug 2023

Timeline

Manufacturing Engineer

BorgWarner (Delphi Technologies - TMD)
04.2022 - Current

Lean Engineer

BorgWarner (Delphi Technologies - TMD)
08.2021 - 04.2022

Industrial Engineer

Spencer Butcher Group
06.2020 - 08.2021

Lean Manufacturing Intern

BorgWarner (Delphi Technologies - TMD)
07.2019 - 05.2020

Master of Science in Industrial Engineering -

Wayne State University

Bachelor of Engineering in Instrumentation Engineering -

University of Mumbai

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PRASAD JOGLEKAR