Siddharth Bhukta

• Executed MOST-based time and motion studies across multiple FDA-regulated assembly operations, establishing standardized cycle times and achieving 14% improvement in labor utilization. • Performed takt time analysis and line balancing across production cells, resolving 4 critical bottlenecks and increasing line throughput by 22 parts/hour. • Analyzed multi-shift production data incorporating setup durations, scheduled breaks, and operator fatigue factors to recalibrate capacity models, improving schedule adherence and on-time delivery by 11%. • Developed and deployed standard work instructions and visual controls on the shop floor, reducing process variation and driving a 9% improvement in first-pass yield. • Led Lean transformation initiatives encompassing 5S, SMED, and structured waste elimination, cutting non-value-added motion and changeover setup time by 18% across targeted production lines. • Conducted scrap and defect trend analysis using Pareto charts and Statistical Process Control (SPC) to prioritize root cause investigations and support CAPA closure in compliance with FDA quality standards. • Partnered with Quality Assurance and Production teams to revise and update PFMEA documentation and process control plans, ensuring full alignment with FDA-regulated manufacturing requirements and ISO protocols. • Redesigned workstation layouts using ergonomic principles and material flow analysis, reducing operator strain and decreasing material handling time by 16%. • Engineered Excel and Power BI dashboards to track real-time KPIs including OEE, cycle time, yield, and NCR trends, providing actionable insights that accelerate data-driven decision-making across the floor.

• Conducted value stream mapping and layout optimization projects across 2 production lines, eliminating material flow inefficiencies and idle workstation delays, resulting in 18% process improvement and 25% reduction in WIP inventory. • Implemented 5S and visual management systems on production floors, enhancing workspace organization and reducing equipment search time, improving material organization and increasing throughput by 10%. • Automated material planning using SAP ERP, MRP systems, and Excel dashboards, enabling proactive stock tracking and schedule accuracy, maintaining 98% material availability and reducing planning errors by 20%. • Authored and standardized SOPs aligned with ISO 9001 and 14001 compliances, improving employee adherence to QA protocols, directly contributing to 7% improvement in right-first-time quality. • Drove CI efforts to improve equipment reliability, raising OEE by 10% through downtime analysis and targeted corrective actions.

• Led 5 lean projects (Kaizen, 5S, TPM) in assembly operations, using Statistical Process Control (SPC) and Control Charts, driving consistent production flow improvements and operator engagement, to achieve 8% efficiency improvement and 12% waste reduction. • Performed capacity planning and production line configuration using AutoCAD and SolidWorks, refining layout logic for balanced workstation loads, increasing vehicle throughput by 5% per shift. • Collaborated on JIT and inventory optimization projects, reducing scrap by 10% and aligning the supply chain precisely with takt time requirements across multiple product families. • Created Excel VBA macros to automate quality dashboards, enhancing visibility for floor supervisors and engineers, leading to 6% improvement in FPY and streamlined daily reporting processes. • Trained 30+ shop floor personnel on MES Systems and digital SOPs, standardizing operational practices and improving digital fluency, resulting in 5% drop in safety incidents and higher compliance with protocols.