Vaibhav Khakkar
Canton,MI
Summary
Experienced Manufacturing Engineer with a proven track record in the automotive industry. Demonstrated expertise in lean manufacturing, process layouts, product development, and error-proofing techniques. Skilled at overseeing manufacturing programs and ensuring smooth operations. Utilizes strategic planning and problem-solving skills to drive productivity improvements. Known for fostering team collaboration and promoting a culture of continuous improvement. Holds a Master of Science (MS) in Manufacturing Engineering from Wayne State University.
Overview
12
12
years of professional experience
Work History
Manufacturing Program Manager
Quality Metalcraft
08.2021 - Current
- Worked as Manufacturing Program Manager (Rivian, Lucid, Zoox, GM, FCA & Ford)
- Lead Program Kickoff with launch and plant team
- Perform Design Reviews with Engineer Team for Fixture, Assembly, Die and Cell Layout
- Provide Manufacturing process guidance to estimating and quoting operations
- Managing new engineering changes
- Performing Financial Calculation
- Providing Engineering inputs for Manufacturing process
- Co-ordination with Customer, Supplier, Supply Chain, Production & Quality team
- Lead Engineering Changes for All Program Management Team and Provide Engineering support
- Providing and processing detail timeline for customer
- Keeping track of timeline and open issue from suppliers
- Collaborated with engineering teams to design customized solutions for unique client requirements, resulting in increased customer satisfaction rates.
- Continuously improved manufacturing processes through regular performance evaluations, root cause analyses, and corrective action implementation.
Manufacturing and Processes Engineer
Quality Metalcraft
01.2017 - 07.2021
- Area Spot welding manufacturing and process (Building 4)
- Designing fixture for new product manufacturing using CATIA V5
- Re-Designing fixture for current product to reduce downtime and quality alerts
- Robot Programming for cell setup and part setup
- Remodeling Cell Layout for improving production
- Maintain production cycle and keeping downtime low
- Analysis and root cause of downtime
- Maintain weekly and daily robotic downtime and production data
- Red Rabbits Error proofing procedures
- Cycle time and time studies for weld cells
- Kaizen implementation and 5s on weld cells
- Area Prototype manufacturing and process (Building 2)
- Developing layout for prototype product launch
- Kaizen on manual re-spot area
- Providing detail cycle time studies on each process
- Implementation of time studies to reduce cycle time
- Providing visual management and visual aid on manufacturing process
Engineering Intern, Machine Component Division
Bharat Forge
01.2013 - 12.2013
- Quality checked using magna flux machine for crankshaft and inspected cracks to avoid failures
- Mechanical design of clamps and fixture for Magna-Flux machines
- Eliminated damage to the crankshaft on machine and improved life cycle of meshed wired plates
- Implemented 5S in Machine Component Division, maximized resource allocation, and improved working condition on 11 lines
- Recalibrated Super Finishing Machine to reduce oil consumption
- Improved filtration of oil to maximize life cycle and quality of super finishing
Education
Master of Science - Manufacturing Engineering
Wayne State University
Detroit, Michigan05.2017
Specialization - Mechanical Systems Design
Symbiosis International University
Pune, Maharashtra05.2014
Skills
- CAD Designing
- Robotic
- PLC
- Plant Layouts
- Manufacturing Procedure Optimization
- Error Proofing process
- Preventative Maintenance
- Robotics Simulation
- FANUC programming
- NACHI programming
- Draft Sight
- Catia part design
- Drafting tools
- Solidworks
- Process Mapping
- Validation
- Pneumatic system
- Spot welding
- Arc welding
- Clinching
- Riveting
- Torquing
- Adhesive system
- Sheet metal stamping
- Hydraulics systems
Professional Projects
- Rivian, EDV Skateboard (Engineering Kick off, Processing, Design buyoff, Cell Manufacturing and Implementation), RT1 Skid Plate (Design Buyoff, Cell Manufacturing and Implementation), Pedal Bracket (Design Buyoff, Cell Manufacturing and Implementation)
- Zoox, Zoox Chassis Component 10 different parts (Engineering Kick off, Processing, Design buyoff, Cell Manufacturing and Implementation)
- Lucid, Lucid Air and Sapphire Component 18 different assemblies (Engineering Kick off, Processing, Design buyoff, Cell Manufacturing and Implementation)
- Ford, Oil Pan Mustang (Design Buyoff, Cell Manufacturing and Implementation), 8 Mig parts for Ford F250 (Cell Manufacturing and Implementation)
- GM, GM Bolt Line 12 Assemblies (Engineering Kick off, Processing, Design buyoff, Cell Manufacturing and Implementation), GM Volt line (Manufacturing and Lean updates), GM Corvette Floor (Manufacturing and Lean updates), GM CT 6 20 Assemblies (Manufacturing and Lean updates)
Timeline
Manufacturing Program Manager
Quality Metalcraft
08.2021 - Current
Manufacturing and Processes Engineer
Quality Metalcraft
01.2017 - 07.2021
Engineering Intern, Machine Component Division
Bharat Forge
01.2013 - 12.2013
Specialization - Mechanical Systems Design
Symbiosis International University
Master of Science - Manufacturing Engineering
Wayne State University
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