Shujaat Raza Zaidi Syed
Brampton,ON
Summary
Results-oriented Process Engineer with a successful track record of optimizing manufacturing processes over five years. Skilled in identifying and implementing improvements to increase efficiency, reduce costs, and enhance overall productivity.
Overview
9
9
years of professional experience
1
1
Certification
Work History
Senior Process Engineer
FLEX N GATE
08.2022 - Current
- Conduct time studies and utilize root-cause problem-solving methods to resolve process issues
- Create and update PFMEAs for existing and new GM manufacturing processes
- Implemented new production technology for Rivet Insertion.
- Obtained $40,000 of labor savings per year.
- Review technical drawings (GD&T) and mechanical design with product engineers for new product launches
- Update monthly measurables (KPIs), present monthly cost savings, and prepare capital expenditure budget to present to Plant Manager
- Provide technical support to maintenance and production departments to avoid downtime
- Identify quality improvements and defect prevention by developing and implementing mistake/error-proofing fixtures and devices
- Resource machining inserts and tooling, resulting in annual savings of over $100,000
- Supervise and assist engineering co-op students in daily tasks and work term projects
- Support material department with equipment quotes and perform cost comparisons
- Provide process training to production on new processes by creating standard operating procedures (SOPs)
- Led cross-functional teams to implement continuous improvement initiatives and ensure adherence to industry standards.
Manufacturing Engineering Co-op
MAGNA INTERNATIONAL
09.2021 - 12.2021
- Reduced idle time in every shift by up to 40% between material handler and team leader by introducing Andon station at every station to drop material when required
- Performed cycle time study and created man-machine charts
- Starting from material pick up out of bin to place on tool and end up with spaghetti diagrams
- Identified bottleneck process and highlighted improvement areas to save operator walking time by improving communication method.
- Performed downtime analysis, specifically looking deep into Pareto charts to identify root cause of line breakdown
- PFMEA Analysis and suggesting ideas for top 3 RPNs every month
- Assisted Area Leader in project launch of Ford Raptor production line through meetings with contractor to perform scheduled activities
- Bin selection of new parts and their effective utilization for Ford Raptor line
- Layout simplification of Ford Ranger line on AutoCAD by optimizing layers
- Design new part bins and arrange quotes for Ford Raptor line to effectively utilize floor layout.
Assistant Manager Production
ATLAS AUTOS PRIVATE LIMITED (HONDA)
03.2017 - 12.2020
- Executed in-house team project of carburetor manufacturing and chromatin in Pakistan with Keihin Japan, resulting in over $1 Million of cost savings
- Technical and managerial experience in supervising machining & and surface treatment of GCI & Zn parts
- Managed and coached team of 70 production associates with help of 3 team leads.
- Performed Continuous improvement using lean tools such as kaizen, Ishikawa, 5S, and 5-whys.
- Improved Cutting tools efficiency by 40% through resourcing and localization.
- Work coherently with QA team to ensure best product quality as per defined KPIs.
- Executed in-house project of carburetor manufacturing and chromating in Pakistan with Keihin Japan
- Performed improvements in Production documents and cross-training of production staff.
Manufacturing Engineering Co-op
English Biscuit Manufacturers
06.2016 - 07.2016
- Performed Cooling load calculations of packing area using HAP software to reduce energy losses by 10% in plant operational cost.
- Created work instructions for packing process and provided training to 25 operators.
Manufacturing Engineering Co-op
HINO Pak Motors
06.2015 - 07.2015
- Designed and proposed 2D-floor layout on Auto CAD for assigned project and performed Kaizen to improve handling time by up to 3 seconds for sub-assembly process
- Performed cycle time studies to identify process bottlenecks.
Education
Master of Manufacturing Engineering -
McMaster University
Hamilton, ON04.2022
Bachelor of Mechanical Engineering -
NED University
Karachi, PK01.2017
Skills
- Process Control (PFMEA)
- CAD (Auto CAD, Solid Works & Key Creator)
- Process Improvement (Kaizen)
- Automation (PLC & HMI)
- Vision System and Bar code readers
- Product Development
- Cost Reduction
- Process troubleshooting
- Prototyping (3D Printing)
- Root Cause Analysis
- Enterprise Resource Planning (SAP, Maximo)
Certification
Lean Six Sigma Green Belt (Six Sigma Global Institute)
Languages
English
Full Professional
Timeline
Senior Process Engineer
FLEX N GATE
08.2022 - Current
Manufacturing Engineering Co-op
MAGNA INTERNATIONAL
09.2021 - 12.2021
Assistant Manager Production
ATLAS AUTOS PRIVATE LIMITED (HONDA)
03.2017 - 12.2020
Manufacturing Engineering Co-op
English Biscuit Manufacturers
06.2016 - 07.2016
Manufacturing Engineering Co-op
HINO Pak Motors
06.2015 - 07.2015
Master of Manufacturing Engineering -
McMaster University
Bachelor of Mechanical Engineering -
NED University
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