Sanjay Narayan
Burlington,ON
Summary
Six years of professional excellence in optimizing a production process by minimizing lead times; identifying and developing key KPIs to monitor the process; managing production schedules; supply chain management; sourcing various type of products (casting/forging/machining) from different vendors; plant and warehouse operations for high growth organizations. Performance track record in managing production processes, preventing wastage, applying lean methods and maintaining manufacturing routes to maximise effectiveness, efficiency and space. Adept at organisation and coordination of production planning, minimising risks and managing costs without compromise in quality. Expert knowledge in data analysis using Microsoft Power BI & Excel.
Overview
11
11
years of professional experience
Work History
PROCESS ENGINEER SPECIALIST - MANUFACTURING
Arcelor Mittal Dofasco
04.2022 - Current
- Ensure Manufacturing Technology Processes realize Business Unit and Corporate goals to achieve a competitive advantage in the areas of manufacturing through process capability, stability and improvement of company’s products, processes and facilities/equipment
- Key Achievements:
- Business System Owner (BSO) of Logistics software being used by the department
- Responsible for managing the equipment fleet, its performance, manage Change Management through Service Now and any issues with the software with the German client
- Evaluate process and product failures and consequences using formal Root Cause Analysis to develop appropriate corrective solutions, controls and training for eliminating/mitigating potential failure(s)
- Build and run queries in SQL Developer and designed reports in MS Excel & Power BI
- Work closely with Operations, Maintenance, Quality Control, Procurement and Project Engineering to scope, develop and execute business improvement projects
- Fleet and Material Management software upgrade project
- The system has played a critical role in supporting business decisions and providing much more data driven decision making
- In so doing the company has achieved several millions of dollars in savings through fleet optimization and management opportunities afforded by utilizing the program
- The company has been able to manage our fleet size effectively and develop robust reporting systems
- With this upgrade, the software transitions into a web-based interface providing sleek design, more user-friendly features
- Acted as a Project Manager in the software upgrade project
- In this role, I managed effective resource utilization; ensuring the client meet their deadlines; used Agile technology to manage the project; regular scheduled scrum updates to the project stakeholders; assisted in testing the new software version for bugs/issues; was the point of contact for approving invoices based on deliverables; working on developing end-user training documents & train the end-users on the new version
- We were able to restructure our workforce involved in dispatching for a net reduction of 8 persons from that process for savings more than $800,000 / year
- Technology Projects
- Created report that captures the amount of purchased material vs forecast and is sent automatically on a daily basis to the Executives
- Created a report that captures utilization and availability (in %) of each equipment type
- Responsible for managing the Quality targets for the Business Unit and also to ensure the Business Unit is compliant during internal and external Quality audits
- Member of Process Engineer committee where we collaborate with other Process Engineers within the company for networking activities, departmental development through exchange of innovative ideas and share latest technologies to enhance productivity and transform the way we work.
SENIOR PROCESS ENGINEER - MANUFACTURING
05.2021 - 03.2022
- Ensure Manufacturing Technology Processes realize Business Unit and Corporate goals to achieve a competitive advantage in the areas of manufacturing through process capability, stability and improvement of company’s products, processes and facilities/equipment
- Key Achievements:
- Technology Projects
- Delivered an automated process of generating electronic version of “Product Transfer Report (PTR)”
- This was achieved by leveraging Microsoft tools such as PowerApps, Power Automate, Excel Business Online connector and OneDrive to generate PDFs
- Manual process of generating PTRs was completely removed by this efficient process and helped reducing the workload for the Area Leaders
- POWER BI:
- Developed KPI’s for each area (Operations (WIP & RAW) & Maintenance) with interactive dashboards in Power BI
- Received appreciation for the presentation on KPI reports to the Management
- Communicated recommendations to leadership, operations and maintenance for process improvements based on the analysis from the KPI visuals developed in Power BI
- PAGINATED REPORT (POWER BI REPORT BUILDER)
- Designed various KPI reports such as Raw Material Purchase summary and Scrap Handling summary in a printable format and triggered the reports in email to Senior Leadership group
- POWER APPS:
- Developed an interactive app to communicate between Logistics & Downstream Production departments about material flow requirement
- Designed an app for Maintenance department to record, track & monitor status of equipment down
- Designed and delivered a PowerApps to track and monitor maintenance employees vacation schedule
- This app helped the Managers in better utilization of workforce and helped them keeping track of upcoming vacations of their employees
- POWER AUTOMATE:
- Utilized Power Automate technology to trigger emails, approval flows, summary of equipment down report & summary of Preventive Maintenance Equipment Wash schedule
- Member of Process Engineer committee where we collaborate with other Process Engineers within the company for networking activities, departmental development through exchange of innovative ideas and share latest technologies to enhance productivity and transform the way we work.
PROCESS ENGINEER
04.2019 - 04.2021
- Ensure Manufacturing Technology Processes realize Business Unit and Corporate goals to achieve a competitive advantage in the areas of manufacturing through process capability, stability and improvement of company’s products, processes and facilities/equipment
- Key Achievements:
- Process/Industrial Engineering Projects:
- Participated in Continuous Improvement of both Equipment and Product/Process performance, thereby improving the overall Business Unit performance (material, labour & equipment)
- Solely managed a field project “Mobile Relief” that enhanced the process of material delivery to internal customers by reducing the time taken to commute and as result increased the number of completed work orders
- Played as a key contributor in developing KPI dashboards in Power BI that tracked Budget vs Actual spend and identified performance levels of different Business Units
- Participated in benchmarking activities, identifying performance gaps and the development of plans to close the gaps
- Observed 10% reduction in time taken to deliver the material and 15% increase in utilization of equipment
- Developed graphs that forecasted the trend of actual spend that helps the Business Units to keep on track with the budget
- Interacted with Leaders and developed a Process Flow Map of the business in MS Visio
- Lead and participated in the development of risk mitigation tools such as FMEA and Control Plans in compliance with the IATF 16949 requirements
- Member of Process Engineer committee where we collaborate with other Process Engineers within the company for networking activities, departmental development through exchange of innovative ideas and share latest technologies to enhance productivity and transform the way we work.
PRODUCTION COORDINATOR
Weston Foods
12.2017 - 03.2019
- Provide leadership and work schedules to guide all the production operations
- Support in strategy execution through technical support and supervision to the team
- Function as a key member of the Health and Safety Committee and enforce OHS procedures and guidelines for operation
- Key Achievements:
- Executed Industrial Engineering concepts to reduce the run length on the conveyor belt of a production line, which increased the efficiency of the line by 30%
- Lead and develop a team on a Continuous Improvement project to improve the quality of cakes being produced
- Conduct shift change meetings and ensure the information is passed on smoothly so that the production requirements are met
- Coordinate all the work operations by creating work schedules, report Key Metric Units (KPI) to the Plant Manager on a daily basis and constant communication with the Supply Planner on daily production results
- Ensure smooth logistics function by working closely with the shipping team and also aid in optimizing inventory management
- Supervise a team to ensure safe work environment & facilitate routine Health & Safety meetings and sessions to create awareness and cement a culture of safety practice within the plant.
JUNIOR SOURCING ENGINEER
Actuant India Private Limited
11.2012 - 07.2015
- Spearheaded the process to expand sourcing and supply chain operation through identifying and establishing strong links with suppliers at a global and regional level
- Key Achievements:
- Improved the process of acquiring quotations from vendors by 65% utilising the MS Excel, increasing efficiency, reducing wastage and saving time
- Designed and implemented a global supplier database with a Request for Quotation (RFQ) tracker to identify potential vendors, float RFQs and enable the retrieval of receipts of quotations on-time from multiple suppliers
- Initiated a benchmarking exercise against US sites and adopted US business Units (BU’s) to aid in bridging the operational gaps
- Functioned as the point of contact between key stakeholders including vendors, business units and the company, received and negotiated for quotations within the budget allocated
- Facilitated the purchase order processing, issuance to vendors for raw materials and updating in the Oracle order management system
- Followed through the purchase order lifecycle from placement to assigned business segments
- Led team members from multiple departments in the design and finance aspects for the new development programs
- Additional Experience
- Directed a group of 5 people from across the globe & carried out a project successfully at Actuant India Private Limited
- Took the initiative and was in charge of various academic projects carried out during Bachelor’s and Master’s degree
- Led a team to victory in the Cricket tournament conducted at Actuant India in 2014
- Captained Cricket (Indian outdoor sport) team at school level from age 13
Education
Master - Engineering, Industrial Engineering
University of Windsor
2017
Bachelor - Engineering
Major - Mechanical Engineering
BMS Institute of Technology
2012
Skills
- Highlights of Expertise
- Supply Chain Management
- Strategic Sourcing
- Scheduling, ERP Software (BaaN)
- Power Apps, Power Automate, Visio & InfoPath
- Warehouse Distribution, Logistics
- Power BI & Power BI Report Builder
- MS Office & SQL Developer
- Lean Manufacturing System
- Group Technology, Line Balancing, 5S
- Occupational Health and Safety
- Continuous Improvement
- Value Stream Mapping
- Process Planning
- Report Generation
- Industrial Engineering
- Root Cause Analysis
- Lean Manufacturing Principles
Timeline
PROCESS ENGINEER SPECIALIST - MANUFACTURING
Arcelor Mittal Dofasco
04.2022 - Current
SENIOR PROCESS ENGINEER - MANUFACTURING
05.2021 - 03.2022
PROCESS ENGINEER
04.2019 - 04.2021
PRODUCTION COORDINATOR
Weston Foods
12.2017 - 03.2019
JUNIOR SOURCING ENGINEER
Actuant India Private Limited
11.2012 - 07.2015
Master - Engineering, Industrial Engineering
University of Windsor
Bachelor - Engineering
Major - Mechanical Engineering
BMS Institute of Technology
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