Rahul Krishnan

Managed over 40 international & domestic vendors for consistent raw material supply , MRO components and services Analyze MRP and Demand to determine proper purchasing timing and quantities. Review and set up of inventory and safety stock levels in the ERP system to achieve the target service level Interfaced with engineering, product management to reduce the raw material / part variety, thus better economies of scale resulted in cost savings Introduced a number of new suppliers and interfaced with engineering and production to establish acceptable product quality specs Identified alternative sources for materials, encouraged quoting based on longer term business potential, eliminated single vendor source dependencies Periodically reviewed the customer forecast and proportionately altered the orders with vendors in order to keep the cashflow inline Established and reviewed cycle count plans monthly to help the inventory and purchasing accurate Implemented vendor stocking programs for raw materials to achieve JIT production Negotiated and maintained vendor agreements and other purchase receipt documentation, created and issued Purchase Orders Supervision of the receiving / inbound logistics Resolution of invoicing discrepancies (pricing/ receipt quantity) Worked up the costing for the products and also evaluated the costs for special custom orders /projects Developed and maintained SOPs for procurement related activities

Established and maintained appropriate quality management documentation, standard work procedures (SOP) for consistency Corrective and Preventive actions CAPA implementation Improved assembly time by 31 % using line balancing technique and lean concepts Led DMAIC project for anodized aluminum color match quality complaints, eliminated root cause and re-established acceptable product quality standards Revamped the shop floor to meet the OSHA standards and inculcated a culture of continuous improvement Redesigned facility floor layout, resulted in 30% increase in throughput and reduced net material handling by 56% Improved tooling to facilitate reduced set up time and reduction of labor Revised Bill of Materials, Maintained ERP system data for production plan and ensured data accuracy, enabling informed decision making. Proficient with Data Analysis and Visualization,Pivot Tables CNC Programming and nesting of products on bills of material for manufacture of sheet metal punching and cutting operations

Developed a value stream map for the current state of production process to identify the potential bottle neck areas / departments Created process flow diagrams & time/motion studies of the work in progress and documented the machining capabilities of the various machines using discrete event simulation software Arena to study the utilization of personnel and machinery Forecasted the demand using exponential smoothing, regression analysis and learning curve methods Developed a production schedule with no tardy jobs & resulting in improvement of lead time by 14 hours

Served as a liaison between Omantec LLC, Buffalo and University at Buffalo, on the durability testing and biocompatibility validation project of their new state of the art patient lift prototype. Developed testing methods, product validation, and defined/optimized specifications Identified and ensured conformance to UL and CFR 820 medical device standards Led a team of 5 students ensuring, deadlines were met, deliverables aligned with client requirements

Applied the DMAIC process to improve the quality of service and for the efficient management of the supplies inventory Reduction of the patient data retrieval time from 4-5 hours to 10 minutes by the application of the Single minute exchange of dies (SMED) concept

Worked as a part of the project management team for the facility augmentation and the mechanical maintenance team as well and also was actively involved in waste/cost reduction initiatives Supported in the streamlining of the production process, the (Kaizen) continuous improvement initiatives and TQM implementation Developed standard work instruction documents/ standard operating procedures for the technicians on the shop floor and worked on putting together a standard training manual for new technicians Implemented lean manufacturing, 5S for the shop floor and Poke-yoke error proofing to eliminate operator variability Coordinated and oversaw the construction, installation and maintenance projects for Steel Melting Shop-2 facility Participated in cross-functional team meetings to update PFMEA documents for machinery and equipment Conducted cycle time and setup time study in the various operating stations in steel making for process refinement, equipment reliability assessment & performance analysis(OEE), utilization and preventive maintenance reviews

Studied the Inventory and Stores organization and performed ABC analysis Regulated the conformance using 8D’s, Root cause analysis Presented a suggestion for the implementation of a deterministic model for reduced investment based on the historic demands Streamlined the vehicle check procedure and benchmarking on the current service practices of competitors in terms of vehicle return time and presented the metrics to the management

Conducted design feasibility study on the traditional gravity die casting process for the manufacture of the valve bodies Investigated the process - work flow, time studies, created value stream maps for the current state & future target state and developed a model for automation of the casting process Carried out a layout study of the machining shop and developed machining capability chart for each machine Optimized the job batches for the reduced buffer or work in-process