NIKHIL PAL

• Lead Operational Excellence Function for the newly setup Green Field site
• Implement TPS based PPI System for the site which consist of -
• Lean Leadership (Daily Management, Leader Standard Work, and Gemba Walks)
• Strategy Deployment and Value-stream mapping
• Kaizen events on standard work, cell design, process and product 3P, Value-Analysis/Value Engineering, error-proofing, material flow, Heijunka, and Kanban
• Lead the Smart Manufacturing Initiatives for the site which consist of following initiatives

Measuring and Improving Ramp up curve

Digital Kanban Solution for Indirect Material

• AR/VR Solution for Training Delivery enhancement
• Flexsim simulation for Line Layout and productivity enhancement
• Wireless Andon deployment for real time production status and downtime tracking
• Introduce UiPath RPA for the Repetitive daily reporting process in Purchasing, Planning and HR function for reporting automation
• Results:
• Productivity Ramp up from 40% to 95% in 6 months for new site meeting the Annual Revenue Target
• Supply Chain Re-alignment enable direct procurement and packaging localization resulting in Hard Savings of $ 400K per annum
• Deployment of Smart Manufacturing Initiatives resulting in Hard Savings of $230K per annum.

• Define and Roadmap for Plan the Factory of the Future (Industry 4.0) roadmap for the Site
• Conducted the SIRI (Smart Industry Readiness Index) by TUV SUD & EDB Singapore
• Drive the PoC (Proof of Concepts) Plan for the new technology introduction in the Manufacturing
• Deployed the AR (Augmented Reality) Solution for Operator Learning to reduce Training time from 4 Weeks to 2 Weeks using PTC Vuforia and Microsoft HoloLens
• Setup the Smart Glass Picking using the RealWear for the Warehouse environment to reduce the Picking time by 50%
• Drive the Change Management in the organization by effective communication and workshops
• Identification of high impact automation projects for the site
• Responsible for the design of Automated Assembly Line for medical devices
• Managing the Team of Software Programmers and developing capabilities for AI (Artificial Intelligence) & Machine Learning (ML) Capability for the Predictive Maintenance
• Step by Step Digital Assembly Instructions for the Complex Assembly product using Solid Works & Bosch Rexroth solutions
• Winner of MTI (Manufacturing Technology & Innovation) Award from Jabil in 2020.

• Drive the Lean Shop floor certification (Lean Training and Certification focused on Daily Kaizen, Waste Identification and 5s) for the frontline employees
• 2 Classroom training every month
• Drive the Lean Bronze Certification program by conducting the classroom training focused on the Practical Problem Solving (A3 Thinking / PDCA) and 7 QC tools for the middle level staff of the site
• Coaching and Mentoring of the Lean Silver Certification Candidates to understand the concepts in the Value Stream Transformation with Value Stream Mapping method
• Conduct the Periodic Classroom Training for the DMAIC/DMADV Methods to coach the ongoing project teams with the Lean Six sigma tools
• Engagement:
• Focus on deployment and enhancement of Lean Culture in the site
• Facilitated and Lead the Strategy Deployment (Hoshin Kanri) 3 Year Strategic Objectives for the Site along with Management team
• Total 6 sessions Conducted since 2018
• Deployment and Training of Strategy Deployment X-Matrix to keep track of the project and initiatives to meet the Strategic Objectives
• Engage the Site Operations, Business and Finance Managers to establish High Impact Project pipe line for the Site and conduct review in the Lean Council Meeting
• Establishment of Project pipeline for each Function and Workcell area in the site for each Fiscal Year focused on delivering Hard Savings to reduce the Transformation Cost
• Drive the Kaizen Events to introduce Basic Stability in the process by introducing Leader Standard Work and Standard Work for the process
• Introduced the TPM (Total Productive Maintenance) for the 3D Printing Machinery
• Quality level mapping in the site to gauge the current state of Built in Quality to promote Poka Yoke and Auto Quality Matrix tools in the Workcell
• Established the Reward and Recognition Program for the Best Kaizen blitz, Best Process and Best System Kaizen
• Lead and Conduct the Annual Deliver Best Practices Competition in the Site to promote the Best Practices proliferation
• Coach and Mentor the employees to improve the Velocity in the Value Stream by injecting the concepts of Material Replenishment, Layout Design, SMED & Lean Scheduling (Heijunka)

• Exceeded all expectations in Plant Layout Planning & Designing, & OEE Improvements, Lean Assessment & Project Management, DL Rightsizing, Resource Management & Optimization, and Workstation Designing / Ergonomic Assessments
• Lead the Complex Assembly Manufacturing for Home Appliance, Automotive and Electronic Measurement equipment
• Diligently maintained Process Routes and Process Control Plan and defined the entire material storage and material replenishment system
• Oversaw Product-Process Matrix & Single piece flow, performed PFMEA/FMEA to improve product/process quality, conducted VSM, and prepared the improvement plan with team
• Proactively expanded professional expertise, became MOST Certified applicator (Basic, Mini) for Applications & Implementations, TAKT Calculations & Line Balancing
• Provided on-time and accurate IE Quotation support to BU to win record amounts of new business
• Responsible for performing DFA analysis where necessary to improve manufacturability
• Recognized as an integral team member in QRQC, JOS, LPA, & Process Audits, and deftly supported NPI builds and collected product data for mass run development and improvement