Rahul Laxman Iyer is a US citizen with a Master's degree in Mechanical Engineering. He is a Six Sigma Black Belt and Lean Manufacturing specialist with experience leading quality improvement and cost reduction projects. Through process optimization and problem solving, he has improved productivity, profitability, and generated new business for various manufacturing companies. He is seeking a long-term opportunity in process improvement and development.
1. Rahul Laxman Iyer
US Citizen
Six Sigma Black Belt & Lean Manufacturing Specialist
Master of Science in Engineering (Mechanical), December
2002
Western Michigan University, Kalamazoo MI USA
rahul_iyer4977@rediffmail.com
Telephone: +1-(623)-428-7032 Mobile: +1-(623)-570-2848
http://www.linkedin.com/in/rahuliyer
220 North 22nd Place Unit 1008 c/o Mrs Pham Thi Phuong
469 Hoang Huu Nam Street
Mesa AZ USA 85213 Long Binh Ward, District 9
Ho Chi Minh City Vietnam
2. Objective & Summary Of Qualifications
Looking for long term opportunity
in process improvement &
development. Trained in Six Sigma
Black Belt & Toyota Production
Systems,experience in
product/machine/fixture design, and
review of new trial parts. I have
lead people, and resolved issues,
improved productivity, increased
profit, and generated new business
utilizing process improvement, and
problem resolution. Demonstrated
history of leading process
improvement, producing accurate,
timely reports,meeting stringent
customer expectations, and
ultimately resulting in cost savings.
Thrive in a deadline-driven and
data-driven environment.
3. • US Citizen
Qualifications
• Master of Science in
Engineering
(Mechanical), Western
Quality Value Michigan University
(Kalamazoo MI USA),
Dec 2002
Customer/Client • Project Management
Satisfaction
Professional (PMP)
(expected Jan 2011)
• Six Sigma Black Belt
Service
(2003)
• Certified Quality
Engineer (ASQ-CQE)
(expected Apr 2011)
4. Qualifications (Continued)
• Languages Spoken
– English (Native Speaker)
– Spanish (Proficient)
Quality Value – Vietnamese (Rudimentary)
– Russian (Rudimentary)
– Tamil (Rudimentary)
• Data Driven
Customer/Client • Proven Track Record Of
Satisfaction Managing & Implementing
Initiatives To Improve
Quality, Cost, & Delivery,
And Delivering Value
• Strong Background in
Service
Supplier Development &
Warranty Reduction/Analysis
5. Needs Served
Toyota Production System
Lean Manufacturing
& Six Sigma Black Belt
Strong, Effective Data Analysis
MSE Mechanical Engineering
Strong, Effective, Process Control,
Optimization, and Cost Savings
Strong Technical Background
Quality Assurance
Data Driven Analysis
& Understanding Of Technical Concerns
Customer/Supplier Relations
Creative, Effective, Measurable,
Solutions & Results
Root Cause Analysis
Effective, Measurable,
Creative, Countermeasures
Satisfied Customers,
Fewer Nonconformances,
Reduction in Costs
6. LEAN/SIX SIGMA/KAIZEN/VA/VE
PROJECTS (Cost Savings)
• Jernberg Industries Inc, JII Machining Division
• Lead project to redo layout of two stage CNC machining cell to improve flow & improve quality. Layout
redesigned as a kaizen to address numerous quality issues at the customer in regard to parts missing
operations & low yield. Savings US$200K annual Tools Utilized: Process Mapping, Time
Study, Process Walk, Takt Time, COQ, FPY, CAD/CAM (AutoCAD), Measuring Probes
(Siemens/Moore Data Gauges)
• Dana Corporation
• Lead production plant, total of 20 people in Value Stream Mapping & establishing a Rapid Baseline
among lines of Dana Production Systems (DPS). Information used to develop foundation, set priorities,
and coordinate lean activity for fiscal year, and to mentor and train others in lean concepts and kaizen.
Total of 3 Black Belt opportunities identified, 8 kaizen opportunities identified. Tools Utilized:
Pareto Analysis, Process Mapping/VSM, Financial Analysis/ROI, Kaizen, Time Study,
Process Walk, Takt Time, COQ, Takt Time, FPY
• Mentored, trained, and coached ISO 14000 Coordinator, and Quality Manager in Lean concepts,
kaizen & 5S techniques, and Six Sigma. Quality Manager, and ISO 14000 Coordinator went on to be
certified Six Sigma Green Belts through Dana Corporation. Tools Utilized: Pareto Analysis,
Process Mapping, Kaizen Event, 5S, PDCA, COQ, Takt Time, Hypothesis Testing, SPC,
One-Piece-Flow, Time Study, Root Cause, FMEA/EMEA, QFD/SIPOC, FPY, Cell
Layout, PDCA, Financial Analysis Training
• Lead Six Sigma Black Belt Project, Mentored & Trained Team of 7 people over course of 6 months
(including outsourced paint supplier), Optimizing Driveshaft Painting Process. Savings US$200K
annual. Tools Utilized: Pareto Analysis, Process Mapping, Financial Analysis/ROI,
Hypothesis Testing/ANOVA, Kanban, PDCA, SPC, Root Cause, Fishbone, Why-Why,
COQ, QFD/SIPOC, FPY, P-FMEA
• Lead Six Sigma Black Belt Project, Mentored & Trained Team of 4 people over course of 6 months,
Worker’s Compensation Management Process. Savings US$220K annual. Tools Utilized: Pareto
Analysis, Process Mapping, SPC, Root Cause, COQ, PDCA, EMEA
7. LEAN/SIX SIGMA/KAIZEN/VA/VE
PROJECTS (Cost Savings)--Continued
• Dana Corporation
• Lead Kaizen Event, Mentored & Trained Team of 5 people over one week,
Driveshaft Remanufacturing, reduction of time from 9 days to 4 days to
remanufacture driveshaft, true labor cost of remanufacturing driveshaft
realized. Savings US$170K annual. Tools Utilized: Pareto Analysis,
Process Mapping, 5S-Shadow Board, Time Study, Pokayoke,
Takt Time, One-Piece-Flow, FPY, Cell Layout, Financial
Analysis/Calculating ROI
• Supplier Development, Lead team of 3 people with setting up kanban for
tube cutoff length through kaizen. Savings US$10K annual Tools
Utilized: Process Mapping, Kanban, Milk Runs, SPC, takt time
• Project Manager for a new line of driveshafts that encompassed localizing
five different series (in charge of tooling development, developing and
maintaining project timeline, and assisting Purchasing Manager with
sourcing of components). US$4.2 million in new business annually & and
allowed closing of warehouse for receiving of overseas product (reduction
of 3 people), savings of US$150K annually. Trained & mentored
Production, Maintenance, Quality, and Sales people regarding new
production equipment and driveshafts. Tools Utilized: MS Project,
PERT/CPM, Pareto Analysis (80/20), D-FMEA, P-FMEA, Cell
Layout, ROI
8. LEAN/SIX SIGMA/KAIZEN/VA/VE
PROJECTS (Cost Savings)--Continued
• Dana Corporation
• Value Analysis & Value Engineering (VA/VE) experience with the redesign of a Spicer Axle used in golf carts (designed
42% of the cost out of the product; improved fit, form, function, capitalized on Dana Corporation patent, met target price,
simplified product design, reduced from US$290 to US$170 per part. Savings of US$150K annual). Tools Utilized:
Technical FAST Diagram, Component Breakdown, Function Breakdown, QFD
• Haldex Hydraulics Corporation
• Supplier Development, Lead supplier, total of 3 people, in process improvement in sand casting of grey iron and part
machinability. New specification and expectation developed with foundry and in-house process resulting in reduction of
nonconformances of 30%, reduction of 200% inspection labor of one person. Savings US$25K annual. Tools Utilized:
Pareto Analysis, Cp/Cpk, ANOVA, Hypothesis Testing, Design of Experiments, Process Walk/Mapping,
pokayoke, COQ, Root Cause, Why-Why, Kanban, P-FMEA, Zone Charting/SPC, FPY, Cell Layout
• Supplier Development, Lead supplier of deep drawn cylindrical hydraulic reservoirs in a series of kaizen events aimed at
improving layout of shop floor. Supplier had several presses and related, and the process just did not flow with current
layout. Kaizen efforts lead to reduction of nonconformances by 50%. Savings of US$20K annually. Tools Utilized:
Pareto Analysis, Process Walk/Mapping, pokayoke, COQ, Root Cause, Why-Why, Kanban, P-FMEA,
SPC (P & NP charts), FPY, Cell Layout, 5S, Shadow Boards Aisin Manufacturing Illinois LLC
• Lead efforts to resolve popping noise with powered back door unit through use of Taguchi Design of Experiments (DoE).
Savings US$60K annual Tools Utilized: Pareto Analysis, Root Cause, Why-Why, FPY, Design of
Experiments, Process Walk/Mapping, Cp/Cpk
• Tepro Industries Incorporated
• Lead Kaizen activities in area of finishing at plant, total of 4 people, assisted in-house processes in reduction 200%
inspection in Finishing. Resulted in labor reduction of four people. Savings US$45K annual. Tools Utilized: Pareto
Analysis, Process Walk/Mapping/VSM, Pokayoke, Root Cause, Why-Why, COQ, takt time/ratio 1, FPY
• Supplier Development, Lead team of 4 people in looking at whole picture through monozukuri, covers everything from
logistics, storage, and packaging. Assisted in redoing “milk runs” that cover two suppliers. This was done through kaizen.
Savings of US$7K annual. Tools Utilized: Process Mapping, Process Walk, Kanban, Kaizen, Milk Runs
9. LEAN/SIX SIGMA/KAIZEN/VA/VE
PROJECTS (Cost Savings)--Continued
• Tepro Industries Incorporated
• Supplier Development, Lead team of 4 people, plus 25 suppliers, in
developing, training, educating, and tracking suppliers on process
improvement, including Quality, Cost, and Delivery. Established system to
rate, train, and develop suppliers. Savings of US$25K annually. Tools
Utilized: Process Mapping/Cell Layout, Kanban, Kaizen, 5S,
COQ, FMEA, Shadow Boards
• Supplier Development, Low Cost Carrier (LCC) Countries, assisted in
PPAP’ing, and qualifying 20+ parts moved from Tennessee to Thailand as
far as production. Savings of US$15K annual. Tools Utilized:
APQP/ANPQP, Pareto Analysis, AQL Level 1, COQ, FMEA
• The Timken Company
• 5S Introduction and Education. Increased availability in Wax Injection by
5%. Tools Utilized: Shadow Board/Toolbox, Cell Layout
• Optimization of various molding and shelling techniques, and in mold
shrinkage. Tools Utilized: Design of Experiments
• Vantage Mobility Internationa LLC
• Cost Justification for Process & Module Redesigns on Honda Van retrofit.
Reduction of 1.25 labor hours per vehicle. Tools Utilized:
DFMEA/PFMEA, Process Mapping, 5WhyAnalysis/Why-Why
Analysis/Root Cause, Time Studies
10. ACADEMIC/RESEARCH PROJECTS--
–
Continued
Rose-Hulman Institute of Technology
• Technical Commuunication/Jaipur Foot Workshop (Jaipur,
India) : Wrote a Technical Report on the Jaipur Prosthetic Foot. Report
documented the design, the manufacturing process, and the results and
need for the Jaipur Foot. This included a visit to the Jaipur Foot Workshop
in Jaipur (India), originally setup by P K Sethi MD in Jaipur, and a visit to a
tire/rubber retreader in an village in India. Presentation was also made at
Rose-Hulman of the research on prosthetic foot. Assisted the Jaipur Foot
Workshop in improving process documentation. Tools Utilized: Excel &
Graphical Analysis/Speadsheets, MS Publisher, MS Word,
Graphics Design, Flow Charts/Process Maps, MS PowerPoint
• Machine Design/American Buff International (Paris IL): Consulted
as part of a team with small startup company (no engineers on site, worked
with Production Manager). Company manufactured rotary abrasive
cutting/polishing/finishing wheels. Redesigned rotary assembly equipment
to allow company to manufacture production more efficiently. Assisted in
optimizing specifications of product, and determining process controls.
Simplified assembly process. Savings of US$20K annually. Tools
Utilized: Process Mapping/Standardized Work (Jidoka), Kaizen,
PDCA, COQ, Takt Time, Time Study, Cell Layout, Financial
Analysis/ROI, Machine Design (CAD/CAM—AutoCAD/Pro
Engineer), Design of Experiments (DoE)/Optimization, Excel &
Graphical Analysis/Speadsheets, , Flow Charts/Process Maps,
MS PowerPoint
11. ACADEMIC/RESEARCH PROJECTS--
Continued
– Rose-Hulman Institute of Technology
• Medical Prosthetic Design/Rose-Hulman Ventures (Terre
Haute, IN): Assisted in design and development of an artificial larynx
made of silicone rubber. Tools Utilized: Materials Analysis,
CAD/CAM (AutoCAD/Pro Engineer), Financial Analysis/ROI,
QFD, FDA cGMP & 501K/PMA, MS Excel/Word/PowerPoint
• Facility Layout/Specialty Plastics Inc (Shelburn IN):
Redevelopment and moving of production to new facility. Production
layout of equipment in new facility. Savings of US$100K annually
Tools Utilized: Financial Analysis/ROI/Payback, Production
Cell Layout, Building Requirements, Local regulations &
standards for production facility, Development of utilities to
service new facility, Logistics, MS Excel/Word/PowerPoint
– Western Michigan University
• Advanced Design/Stryker Instruments (Kalamazoo MI):
Redesign of trauma reamer for a 3:1 torque ratio, rather then a lower
torque ratio Tools Utilized: CAD/CAM (AutoCAD/Pro
Engineer), QFD, Component Breakdown/Functional
Breakdown, Gear Design/Analysis, Pugh/TRIZ, MS Project,
DFMEA
12. ACADEMIC/RESEARCH PROJECTS--
Continued
– Western Michigan University
• Project Management/Spring Technologies
Corporation/Petersen North America (Portage MI):
Implementation of Lean in an assembly operation. Savings of
US$170K annually Tools Utilized: Pareto Analysis, Process
Walk/Mapping, pokayoke, COQ, Cell Layouts, Kanban, P-
FMEA, FPY, 5S, Shadow Boards, Project Management, MS
Project, PERT/CPM, Machine Design, Work Instruction,
Pareto Analysis (80/20), Kaizen/Standard Work (Jidoka)
• Two Phase Particle Fluid Flow In Couette With Non-
Spheroidal Particles: Experimental verification of a theoretical CFD
model. CFD model proposed earlier by M Yoda PhD (Georgia Tech) &
D Qi PhD (Western Michigan University). Tools Utilized: Machine
Design, Flow Visualization/Cameras, CFD/Fluent/Fortran
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15. Next Steps
• CONTACT ME!!
• I am actively looking for new
opportunities in the following
geographic locations:
• Metropolitan Phoenix AZ USA
– Phoenix, Mesa, Scottsdale, Tempe,
Chandler, Gilbert, Glendale,
Peoria, and other locations in
metro Phoenix
• Metropolitan Ho Chi Minh City
Vietnam
– District 9/Thu Duc, Binh Duong,
Dong Nai/Bien Hoa, Cu Chi,
Saigon/Ho Chi Minh, Tay Ninh,
Vung Tau/Ba Ria, Long An
