Asif Iqbal

Emhart Teknologies, Chesterfield, MI

April, 2010 - till dateManufacturing Launch Engineer, Injection Molded Plastic. Rubber and Two shot ComponentsProgram Management responsibility for 12 new programs including 60 molds of bumper spacer/bracket for Toyota, Honda and Chrysler as well as small plastic components for GM, Ford and Texas instrument. Hands on experience in modification and updates to plant layout, plant process, capacity calculation and planning, equipment specification & requirements for new program launch. Responsible for implementing Lean Manufacturing , Kaizen waste reduction, man assignment, value stream mapping, lead-time reduction, SMED, 5S,Gemba Walk and floor space savings, Production planning and logistic for lean process, modification of assembly fixtures for error and mistake proofing. Plant/site team leader to coach, train, implement and enforce Lean Principles. Site leader for generating and tarcking of  $0.5M in annual savings.Well rounded, diverse & extended role in Manufacturing and Program Management from development to launch. 

• Leadership in driving consensus and set direction between cross functional teams of design, engineering, quality, program management, product planning and logistics for manufacturing readiness.
• Program Manager /Team Leader to track major milestones and deliverables to ensure parts availability in timely fashion for 12 new programs.
• Manufacturing Program Manager to track CSM forecasts for CPV/FPV and capacity calculation, plan and schedule mold arrival dates, tool tryout for process verification, pre-production process optimization and ramp up.
• Oversaw mold design during design phase and sign off based on plant manufacturability and compatibility.
• Updated current equipments to standardize process in the plant as part of 5S initiative.
• Initiated business case for capital expense, used capacity analysis and calculation with justification and savings of $5M over life of the programs.
• Wrote capital expense package with an investment of over $3M as part of cost saving business case.
• Lead responsibility for budgeting, financing and expenses for expansion project; successfully executed the project within quoted scope.
• Design and developed assembly fixture for error and mistake proofing to eliminate customer concerns.
• Led and drive teams of bargaining unit and achieved aggressive timeline to commission 3 injection molding machine, robot, guarding and auxiliary equipments with in 13 weeks.
• Developed Value stream map (VSM) to identify wait, waste and lead-time, reduced waste by re-allocation and balancing of manpower. Used Kanban for lead-time reduction and SMED activity for setup reduction.

Green/Lean  HVAC System - Extrusion & Injection Molded Components and System Level Assembly

Design and developed plant layout, tooling for fabrication process of core components and final assembly tooling & equipment with Lean manufacturing process for new assembly plant. Leading 5S implementation, tool facility layout, and commissioning of production equipments for full production by July 2010. Provide primary support in design, development , packaging and manufacturing of Injection Molded and Extruded parts of Conditioner & Regenerator.

• Design and developed tooling for two shot Injection molded high temperature plastics distributor; PPSU/PSU.
• Design and developed tooling for two shot Injection Molded clamp manifold for conditioner; PVC/ABS & EPDM.
• Design tooling for automated secondary process of heating and welding of high temperature plastic; PPSU/PSU.
• Design and developed tooling for thermoforming & heat activated welding process of Plastic Heat Exchanger unit
• Manage master time line, evaluate cycle time & generated electronic tooling requirements.
• Design & developed tooling for glue application using intrinsically safe robot per ANSI/RIA R15.06-1999 standard
• Design and developed pneumatic tooling for final assembly operation to install 200lb conditioner assy.
• Coordinate with cross functional team to resolve issue regarding manufacturability of the design (DFM) & (DFA).
• Responsible for product planning, budgeting, sourcing of material, budgetary RFQ for production equipments, cost negotiations, equipment reliability, equipment qualification and sourcing for new assembly plant.
• Direct design activity in re-designing of components to reduce cycle time. Involve in (DV), reliability and testing,
• Establish manufacturing scroll, completed test plan, process methods & process sheets (SOP).

Injection Molded Exterior Systems (2010 WK Jeep Grand Cherokee)

In this role, I provided engineering & project management guidance on conceptual design. Performed benchmarking activities, identification of material and cost reduction opportunities for assign projects. I have conducted 3D modeling activities and assembly design in cross-functional team meetings, deliver PDR & CDR reviews on milestones Participated in APQP, PSO & PPAP meetings and reviewed CMM check & gauge R&R requirements for quality.

• Design and development of extruded molding, two shot injection molded panels and wiper/Washer systems.
• Expertise in composites, used experience in the design & development of roof molding & two shot cowl screen.
• Develop design estimates of piece cost and tooling for assign commodities in project start-up.
• Initiate preliminary test (DVP&R) and supporting analysis (DFMEA, PFMEA) to validate the design & process.
• Develop program bill of materials (BOM). Identify risks areas and stabilize the BOM for new program.
• Supervise documents & drawings. Provide engineering & project management guidance on conceptual design.
• Maintain ETC, EAC report of actual expense compared to contract at completion.

2007 Jeep Wrangler

I was responsible to review and analyze engineering drawing and documents and weekly discussion on manufacturing process, feasibility and equipment layouts.  Implement all corporate releasing requirements such as design analysis, BOM, stampings, fit & finish, tool & gage reviews, framing, functional objective, change management, compliance testing and process sign off (PSO).

• Design and developed Steel & Aluminum components such as Hood assy, BSA, Qtr assy, rails, structures etc.
• In-depth experience of forging, sheet metal stamping, forming, welding & tooling of frames and beams.
• Oversee linear & non-linear FEA analysis, for material characteristics and to analyze component stiffness.
• Excellent knowledge of CAE analysis including stress analysis, crash analysis & durability.
• Provides manufacturing support in technical matters relating to drawing interpretation, engineering change notices, rework manufacturing difficulties and specifications.

2002 Dodge Ram & 2004 Dodge Durango

I was responsible for design; development and packaging of Hard trim interior components. I was also responsible to for FMVSS 201 Head Impact (HIC) testing to comply with NHTSA guide lines. Evaluated FMH videos & Hypergraph to analyze and recommend design change. I also recommended alternative manufacturing methods and processes.

• Responsible for manufacturing and design of injection-molded interior trim panels and IP components.
• Responsible for design changes feasible with tooling condition (slides, die pull, water line & tool action etc).
• Executed DOE to optimize injection-molding process to minimize warping of gas assist trim panel.
• Analyzed Mold Flow for tool design & capability to update gate locations to resolve flow line, knit line etc.
• Implemented FMVSS 201 requirements for head impact & for full frontal impact FMVSS 208 in IP design.
• Implement just-in-time (JIT) Lean manufacturing technique to increase productivity & to reduce plant inventory

Air Inlet Pane ( 2000 Cadillac Deville GMX-270)

As a design release engineer, I was responsible for design, packaging, development and release of two shot injection molded cowl screen based on design office theme and vehicle architecture.Coordinate with cross functional team on packaging and design for quality, participated in advance manufacturing process review.

• Designed & developed wipers/washer cowl screen design for new program from project start-up.
• Initiate preliminary test and supporting analysis (DFMEA, PFMEA, DVP, QBC) to validate the design & Process.
• Incorporates FMVSS &EEC requirements in system and component designs.
• Redesigned air inlet panel for 2001 to pass Universal Water Management test.
• Engineered grommet to achieve commonality across Cadillac & Pontiac platform

2002 MY Jeep & Dodge Assembly Plants

Primary contact engineer responsible for design of engine lifting device.Responsibility in design, development and installation of power train and chassis tooling. Initiated and completed manufacturing scroll build, test plan, procedure, process methods & process sheets (SOP). Manage master time line, determine prototype tooling; evaluate cycle time & generated electronic tooling requirements.Reviewed and evaluated quality and participated in advance manufacturing quality audits to assure process variation reduction and components quality. Duties included reviewing internal (Daily Quality Audits) and external (JD Power Index and Customer Feedback) quality indicators.Coordinate with allied sources, engineers and supporting groups to meet the customers & design intent with customer first attitude.

• Responsible for coordinating design & development activities for power train lifting device to pickup engine from the rack this resulted in zero injuries to the operator, improved throughput and eliminate material damage.
• Responsible to facilitate problems solving to determine root causes, verify corrective actions, using mistake proofing techniques and robust design solutions to drive process improvements with leveraged results.
• Successfully implemented pulse tools on line for ergonomics assembly of fasteners to reduce HPV and overall tooling cost.