YOUNUS SHAH

Leading lean implementation and establishing standard work instructions at Client's facility to ensure superior quality, reduce cost and outstanding output. Direct interaction with plant personnel on implementation of 5S. Conducting Kaizen events to implement lean principles, reduce lead time, reduce inventory and improve changeover time. Promoting new technologies to improve customer cost and improve margins.

Provided training, technical assistance and engineering support to the manufacturing production area. Led the multi-disciplined teams in finding root cause, identify corrective action and containment. Led the corporate quality assurance processes to successfully resolve product and process issues. Used GD&T, statistical analysis, problem solving tools, and good engineering practices to quantify the problems at the assembly plant. Managed projects with cross functional objective.

Led the overall progress of the vehicle design and development projects, from initial concept through production. Ensured project milestones and targets are met. Performed all aspects of vehicle, component, and material testing. Managed source packages for all new product releases, including organizing technical assessment reviews of all suppliers quotations. Created 3D models, bill of material, cost, weight and investment roll up. Led engineering team to identify risk and opportunities for all new features and present it to top management.

Effectively led the team for multiple programs and supervised 5 engineers to develop lightweight structures using Finite Element Analysis (FEA), Testing and Optimization tools. Analyzed full vehicle impact performance. Worked in cross-functional team for truck body structure, in order to comply with Federal Motor Vehicle Safety Standards (FMVSS). Met all cost, weight and quality target as planned.

Worked with cross functional team for sports utility vehicle structure, in order to comply with Corporate and Federal requirements. Involved in designing, testing and analyzing full vehicle structure. Conceived, designed, and prototyped the light-weight steel structures for use in vehicles, resulting in 10% lighter weights which helped improve the fuel efficiency and cost savings. Performed sensitivity analysis to find the effect of structural foam on the characteristics (strength, stiffness, energy absorption) of foam filled structural members.