Summary
Overview
Work History
Education
Skills
Soft Skills
Certification And Courses
Accomplishments
Timeline
Generic

Yogesh Chaudhari

Solon,OH

Summary

A results-driven, dynamic Mechanical Engineering professional with nearly 18 years of experience in leading, planning, and coordinating activities across Manufacturing/Industrial Engineering, Virtual Manufacturing, Robotics & Automation, Layout Planning, Process Planning, and Continuous Improvement programs for both current and new Product Development. Proficient in utilizing and implementing various virtual manufacturing tools and techniques to enhance production processes and facilitate new product development.

With a focus on results and self-driven determination, adept at analyzing and evaluating business needs. Possesses a strong ability to unite teams toward delivering outputs with high proficiency and accuracy.

Overview

22
22
years of professional experience

Work History

Advanced Engineering Manager

Foxconn EV Systems
11.2022 - Current
  • Established Factory Digitization and Product Engineering Capability at Foxconn Ohio to verify Product Manufacturing Feasibility and Process capability across diverse scenarios through simulations and Virtual Validations
  • Built a team of over 10+ high-performing engineers specializing in factory digitization and product engineering, ensuring consistently high-quality output
  • Implemented substantial improvements in the battery production line, enhancing the battery potting process resulting in anticipated cost savings of $1.7 million annually for planned production rates
  • Moreover, this enhancement effectively resolved multiple critical manufacturing issues
  • Developed a comprehensive simulation model for the entire vehicle transfer conveying system spanning Bodyshop, E-coat, sealing line, Paint, Ovens, Final assembly, and End-of-Line operations
  • This model helps in determining the necessary number of carriers and identifying bottleneck areas based on varying Job-per-hour (JPH) requirements
  • It also facilitates planning investment actions to modify systems according to future program requirements
  • Led and coordinated the implementation of Pro-planner, an integrated process planning software application, in collaboration with the Industrial Engineering team
  • Developed a comprehensive engagement strategy with the client's engineering team to proactively spearhead and facilitate Design for Manufacturing (DFM) and Design for Assembly (DFA) initiatives
  • This aims to enhance client product design concerning manufacturing/assembly feasibility, operator safety, and ergonomics and drive commonization among multiple vehicle programs.

Lead NPI Project Engineer

Electrolux
02.2022 - 11.2022
  • Provide Holistic Support for Product development from Concept to Production: Support for new product development spans the entire journey, encompassing concept design through to production launch
  • Involved in New Product Introduction (NPI) projects extends to various critical activities
  • This includes performing detailed DFMEA analysis, conducting virtual product assembly feasibility, orchestrating operation sequencing, and developing visual work instructions
  • Designed and implemented an AI vision-based live defect identification system on critical manufacturing workstations, resulting in a 90% improvement in product quality and a 70% reduction in rework percentage
  • Drive Manufacturing Validation Test (MVT) readiness, ensuring that the production line is primed for testing
  • Additionally, we optimize workstation layouts using the principles of 5S, enhancing part presentation for operators' ease and safety
  • Designed and implemented numerous innovative production aids on the line to streamline assembly processes, enhance operator ergonomics, and reduce time and effort.

Virtual Manufacturing Engineer

LAM Research
09.2021 - 02.2022
  • Streamlined Virtual Build Activities for the Pilot Manufacturing Team
  • Aim to revolutionize the virtual build activities for the Pilot Manufacturing Team, fostering a culture of innovation, precision, and continuous improvement throughout the prototype build journey
  • Identifying and meticulously documenting Design for Assembly (DFA), Design for Fabrication (DFF), and Design for Service (DFS) issues
  • Engaging closely with the product design group to promptly address and resolve identified issues, fostering continuous improvement
  • Orchestrating the creation of a meticulous Manufacturing Bill of Materials (MBOM), Process Plan, and precise work instructions, serving as a roadmap for the Pilot Build phase.

Sr. Industrial Engineer

Electrolux
09.2020 - 09.2021
  • At the forefront of all Industrial Engineering endeavors for the Electrolux Bronco plant, I am entrusted with a comprehensive array of responsibilities, including: Conducting meticulous Time Studies, employing Video Lean Analysis methodologies, and establishing precise time standards to enhance operational efficiency
  • Strategizing operation sequencing, crafting optimal routing plans, and meticulously balancing assembly lines to ensure a seamless and efficient workflow
  • Orchestrating Layout Design and Optimization efforts to create work environments that maximize productivity and spatial efficiency
  • Ensuring operator safety and ergonomic excellence throughout the manufacturing processes, fostering a workspace that prioritizes the well-being of our team members
  • Identifying avenues for Process Improvement and Automation, continually seeking opportunities to enhance processes and integrate automation for heightened efficiency
  • Crafting comprehensive Operator Work Instructions and Training Documents, providing clear guidelines that empower our workforce and ensure consistency in operations.

Operations Manager

Genius Business Solutions
03.2017 - 09.2020
  • Led an accomplished team of engineers in an Onsite Offshore model, I orchestrated the seamless execution of projects encompassing Factory Layout Planning and Optimization, Process Planning and Validation, Lean Technology, and Digital Manufacturing
  • Designed tailored solutions aligned with customer requisites
  • This involves delving into customer challenges, identifying enhancement prospects, evaluating alternate solution concepts, recommending necessary improvement actions, orchestrating execution, and presenting Proof of Concepts (POCs) Led projects to establish time standards (Time Study) for all products using Video Timer Pro
  • For the Sullair Michigan City plant using Factory CAD & Creo software
  • Conducted Video Lean analysis for all product assembly processes, identifying Non-Value Added (NVA) activities
  • Recommended improvement actions to eliminate NVAs, resulting in a 25% reduction in average product build times
  • Created a virtual factory proposing optimized layout concepts in a 1:1 scale 3D environment
  • Conducted facility layout redesign & optimization, freeing up 22% (16,300 sq
  • Ft.) of floor space for new product assembly lines
  • Proposed automation concepts to reduce bottlenecks, improve operational efficiency, and enhance space utilization.

Assistant Manager

Infosys BPM
05.2012 - 02.2017
  • Led a team of 20 engineers in vehicle assembly process planning, layout planning, and virtual validation
  • This involved refining assembly process plans from concept to final stage for various John Deere products
  • The focus was on ensuring assembly sequence accuracy, proper fitments, and optimizing parts and resource utilization throughout the assembly operation.

Manufacturing Engineer I

Dell International
06.2010 - 05.2012
  • Worked on design, development & Planning of assembly-line setup of MWL & MG products for the Caterpillar China Suzhou facility, Perkins engine factory development. & Operation Station factory (Facility for Cabs Manufacturing) factory development.
  • Created Virtual Factory layouts for CAT Decatur, Aurora & Peoria manufacturing facility in 3d
  • Worked on PDTMS (Predetermined Time & Motion Studies) for setting up labor standards.


Sr. Lead Engineer

Mahindra Satyam
10.2007 - 06.2010

Design Engineer

INCAT, Tata Technologies Ltd
02.2007 - 10.2007

Sr. Robotic Engineer

Plazma Technologies (P) Limited
03.2004 - 08.2006

Trainee Engineer

Aurangabad Auto Ancillary (P) Limited
12.2001 - 12.2002

Education

Post Graduate Program in Project Management -

Isenberg School of Management University of Massachusetts

Prost Graduate Diploma in Business Management – Operations Management -

Welinkar Institute of Management Development and Research, India

Engineering Diploma in Production Technology -

State Board of Technical Education, India

Skills

  • Project Management
  • Lean Manufacturing
  • DMAIC Methodology
  • Layout design & Optimization
  • Discrete Event Simulation
  • Digital Manufacturing

Soft Skills

• AutoCAD/SolidWorks/Catia

• Flexsim

• Prop-planner.

• Timer Pro

• Siemens / Technomatix Manufacturing solutions

• Delmia 3ds manufacturing solutions

• Process Simulate

• Factory Cad – Factory Flow

• Microsoft Project Professional

Certification And Courses

  • Six Sigma Green Belt
  • Six Sigma Black Belt
  • PMP (Project Management Professional)
  • Master Certificate in CAD CAM CAE
  • Microsoft Project Professional
  • Agile Scrum Master

Accomplishments

    Promotion to Manager position: Acknowledged for exceptional performance and skills at Foxconn, achieving promotion to a Managerial role within just 4 months of joining the organization.

    Continuous Improvement Incentive at Foxconn: My team received a continuous improvement incentive in recognition of our successful implementation of various enhancement initiatives on the manufacturing floor. These initiatives led to substantial time, effort, and cost savings while also enhancing operator safety and workability.

    Going Above & Beyond Award: Acknowledged by the Electrolux Global Manufacturing Team for exceptional dedication and performance.

    High-Performance Incentive (HPI) Recipient: Recognized for outstanding performance at Infosys, earning this prestigious award for three consecutive years.

    First Place in Best Practice Sharing Competition: Achieved the top position at the organizational level at Infosys by demonstrating expertise and sharing best practices.

Timeline

Advanced Engineering Manager

Foxconn EV Systems
11.2022 - Current

Lead NPI Project Engineer

Electrolux
02.2022 - 11.2022

Virtual Manufacturing Engineer

LAM Research
09.2021 - 02.2022

Sr. Industrial Engineer

Electrolux
09.2020 - 09.2021

Operations Manager

Genius Business Solutions
03.2017 - 09.2020

Assistant Manager

Infosys BPM
05.2012 - 02.2017

Manufacturing Engineer I

Dell International
06.2010 - 05.2012

Sr. Lead Engineer

Mahindra Satyam
10.2007 - 06.2010

Design Engineer

INCAT, Tata Technologies Ltd
02.2007 - 10.2007

Sr. Robotic Engineer

Plazma Technologies (P) Limited
03.2004 - 08.2006

Trainee Engineer

Aurangabad Auto Ancillary (P) Limited
12.2001 - 12.2002

Post Graduate Program in Project Management -

Isenberg School of Management University of Massachusetts

Prost Graduate Diploma in Business Management – Operations Management -

Welinkar Institute of Management Development and Research, India

Engineering Diploma in Production Technology -

State Board of Technical Education, India

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Yogesh Chaudhari