Expert Details

Expert in High Tech Systems Manufacturing Operations

Expert ID: 726398 California, USA

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He has an extensive experience in Design for Assembly of High Tech Systems. He has set up the Assembly process to be smooth with out need for highly customized steps. He has achieved this by breaking the assembly to simple steps and outsourcing to a contract manufacturer with proper documentation. His goal is to optimize assembly time and cost.

He has driven Design For Cost tasks many times in his career. He has achieved phenomenal results with this approach. The key thing he looks for is single sourced items or highly complex items which require extensive labor. In either case, which needs to be dealt with thorough analysis to minimize cost.

DFM is a key deliverable during NPI management. Expert has driven this task many times in his career and has achieved significant results thru this task. Manufacturability depends on the product and business model. He has worked with many suppliers in developing DFM guidelines. DFM also helps in Design for Cost and Design for Assembly tasks.

Design for Testablity should be conducted as early as possible in the hardware design. If the product consists of PCB assemblies, then the test points need to be incorporated in the PCB design. DFT helps in implementing it. DFT at System level should be done before System Hardware and Software is specifications are finalized. Expert has driven this task all thru his career and achieved major very high test coverage which resulted in high product quality and reliability.

Expert has driven this task with passion since quality plays a big role in any manufacturing process. During Hardware design it is necessary that the design engineers are aware of the quality requirements for the products which may in terms ease of use, rugged handling, harsh environment, transporation stress etc.

Electonics manufacturing has been the core experience in Expert's career. He has a hands on experience in Electronics Manufacturing starting from the step of bring in material to the factory to the step of shipping electronic products to customers.He has developed automation for testing, assembly and packaging. Factory management involved key aspects such as resource planning, documentation, goals and metrics. Flexible manufacturing was always one the requirements for him since he believes any process should be able to handle exceptions with flexibility in terms of product flow, product type, configurations etc.

In any manufacturing environment, Inventory Control is the key task since it affects the bottom line of the business directly. Carrying high inventory or low inventory is not good the business. The inventory should be optimum and Expert has achieved it thru thorough demand-forecast analysis. Unless we know Demand and Forecast well, we will be able to control inventory properly. The goal is to have the right amount of inventory available at the right time. This absolutes involves JIT concept very well. Production Control has a lot to contribute in keeping optimum inventory on the floor either in kits or in Kanban.

Expert may consult nationally and internationally, and is also local to the following cities: San Jose, California - San Francisco, California - Sacramento, California - Oakland, California - Stockton, California - Fremont, California - Modesto, California - Salinas, California - Santa Rosa, California - Hayward, California

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Education

Year Degree Subject Institution
Year: 1990 Degree: MS Subject: Electrical Engineering Institution: Northeastern University
Year: 1981 Degree: BS Subject: Mechanical Engineering Institution: Unversity College of Eng, Bangalore, India

Work History

Years Employer Title Department Responsibilities
Years: 2008 to 2008 Employer: Pillar Data Systems Title: Sr Dir of Mfg Operations Department: Operations Responsibilities: Responsible for Mfg Operations team, which consisted of Mfg Eng, Test Eng, Production and Quality functions. Improved Mfg thru-put by 50% with structured efficient processes and optimized cycle times. Improved cycle time through DFM, TQC and Value Stream mapping. Managed Order-Fulfillment and achieved 100% on time shipment performance. Managed Test Development and Implementation. Managed DFT and DFM during product development and achieved very high yields thru mfg tests. Automated System test to incorporate configuration verification against sales orders on Oracle ERP system. Implemented robust manufacturing processes with thorough documentation. Eliminated bottlenecks and incorporated process checklists for operators to perform consistently. Met Corporate Quality and Compliance goals by 100% per ISO, UL and TUV requirements. Implemented CAPA processes in Manufacturing and eliminated legacy non-conformances. Partnered with Tier1 Contract Manufacturer and achieved 99.5% first pass yield, 20% mfg cost reduction and 100% on time delivery. Managed field spares supply and logistics effectively. Reduced Spares Inventory by $0.6M (20% reduction) with consolidating parts and SW versions.
Years: 2004 to 2008 Employer: 3PAR Data Title: Dir of Operations Department: Operations Responsibilities: Managed Operations from start up stage thru public (IPO). Contributed significantly in taking 3PAR thru IPO (Nov/2007). Managed operations effectively to meet the revenue growth from $1M/ Qtr to $40M /Qtr in 4 years. Managed Operations organization with responsibilities in Supply Chain, Logistics, Shipping/Receiving, Production, NPI, Test, Warehousing, Inventory Control, Reverse Logistics, RMA FA and Repair and Field Spares inventory. Built the entire Ops team from ground up and implemented robust processes to handle fast growth.
Implemented Supply Chain team to proactively meet daily production demands with maximum flexibility. Implemented Expert system and improved planning process tremendously. Eliminated shortages by 90% with in three months after implementing Expert. Implemented LEAN Manufacturing with tools such as KAIZEN, Value Stream Mapping, 5S, Kanban, Cellular build, Shopfloor etc. to optimize the thru-put with high Inventory Turn & low Overhead cost. Implemented an effective S&OP process for forecasting and order-fulfillment. Implemented a cost effective outsource model for low volume/high mix product line. Outsourced low skilled manufacturing tasks and improved margins with low material cost and low outside mfg cost. Reduced manufacturing cost by 20% in the first year and maintained low cost model effectively. Managed demand planning and Expert per forecast. Drove production build schedules to meet a goal of 100% on-time shipments consistently. Managed Contract Manufacturers for production of outsourced assemblies such as PCBAs and Chassis. Managed manufacturing readiness reviews to insure proper transition of prototypes to pilot and volume production. Negotiated favorable contracts and low prices with suppliers to meet quarterly price reduction goals.
Managed Quality, Cost and Delivery of multi-tier Supply Chain in US and overseas. Established strong relationship with the executive team and cross-functional peers in Engineering, Marketing, Finance, Sales and HR. Managed global spares depots to provide world class Customer Support. Drove cost effective Supply chain strategy with Engineering and Marketing and achieved low cost and high margins. Represented Operations at Executive briefings and provided executive summary to the Board of Directors (BOD). Managed Sarbanes Oxley (SOX) compliance for Operations as a requirement for going public.
Years: 2001 to 2004 Employer: Luminous Networks Title: Dir of Manufacturing Department: Operations Responsibilities: Managed manufacturing team comprising of Production, Test, Quality and Order-fulfillment functions. Managed turnkey operation with Contract Manufacturers. Reviewed Forecast and Sales Orders and scheduled production builds for Order Fulfillment. Drove continuous improvement of manufacturing processes to meet a goal of 100% on time delivery at low cost with high quality. Managed and expedited material shortages to complete production builds on time and met revenue of $4M/Qtr. Managed New Product Introduction group to build Prototypes. Drove Design For Manufacturability (DFM), Design For Testability (DFT) and Design For Reliability (DFR) during product development. Managed development of Mfg Tests such as ICT, Functional Test, System Test and ESS. Managed field failure analysis effectively, identified root causes and implemented corrective actions.
Years: 2000 to 2001 Employer: Alidian Networks Title: Dir of Supply Chain and Quality Department: Operations Responsibilities: Managed Materials Organization, Suppliers and the Contract Manufacturers for semi turnkey manufacturing. Developed Production Forecasts and Build Plans for order fulfillment. Managed Expert runs, Product Costs, Order Fulfillment, Inventory and AVL. Strategizing with key suppliers for Delivery, Quality and Cost requirements. Reviewed ECOs for Cost, Schedule and Quality requirements. Used Expandable as the ERP system.

Obtained ISO 9001 certification for Alidian within six months from the get-go. Managed Quality Assurance Organization and the Quality System. Managed Corrective and Preventive Action, Supplier Quality, Product Quality and Field Quality systems. Implemented effective business processes across the organization in areas such as Engineering, Product Line Management, Customer Service, Tech Support, Order Fulfillment, Supply Chain Management, Test Engineering, and Production etc. Managed compliance to other standards also such as; Telcordia, NEBS, TUV, UL etc. Managed Product Reliability analysis (MTBF, Availability etc.) group,
Years: 1998 to 2000 Employer: Lucent Technologies (Ascend Commincations) Title: Dir of Quality and PLC Manager Department: Operations Responsibilities: Managed a QA organization consisting of functions like Product Quality Engineering, Document Management and Compliance groups. Developed Strategic Quality Systems and processes. Conducted Management Quality Reviews with the Executive staff. Managed Quality of turnkey services from Tier1 Contract Manufacturers including Far East. Managed compliance to ISO, BABT, Bellcore, TUV, CSA etc.

Responsible for Access Product Line. Managed a PLC group to introduce New Products on time with a goal of higher Quality at each and every release. Managed Test Eng, Mfg Eng, Supply Base Eng, Quality Eng and Material Planning. Developed NPI processes and metrics and drove continuous improvement programs. Developed Product Test strategies, Build plans, Order fulfillment strategies and EOL plans.
Years: 1995 to 1998 Employer: Bay Networks Title: Quality Manager Department: Operations Responsibilities: Managed Quality organization to support Operations and New Product Introductions. Developed field Quality metrics and drove product quality improvement projects. Presented Quality data to customers. Calculated product reliability from field data and drove improvements thru design enhancements. Published actual and predicted MTBF for all the product line. Well versed in Reliability prediction and FMEA techniques.
Years: 1987 to 1995 Employer: Hewlett Packard Title: Sr R & Engineer Department: R&D Responsibilities: Led development project teams to release new products on time, which involved driving resolutions to HW and SW issues. Facilitated design reviews, component reviews & FMEA on new products to eliminate risks and improve design quality. Conducted STRIFE (Stress-Life) tests to eliminate design weak links.

Additional Experience

Training / Seminars
LEAN Training in 2007.
Vendor Selection
Selected Contract Manufacturers at multiple jobs thru extensive analysis (Solectron, Flextronics, Flash Electronics and Sanmina). Also have selected component suppliers like Hitachi, Seagate, Fujitsu, Xylinx, AMCC, Power One etc.
Marketing Experience
Have a thorough understanding of Networking and Storage Systems Industries.
Other Relevant Experience
Over 20 years of experience in Manufacturing, Supply Chain, Materials, New Product Introduction (NPI), Product Life Cycle Management (PLC), Customer Service Operations, Quality Management and Reliability Engineering. Highly focused Operations leader with extensive experience in championing substantial cost reduction, quality improvement and best delivery performance for Start-Up and Fortune 500 companies. Proven ability to initiate creative manufacturing and supply chain programs delivering immediate results. Expertise in revitalizing organizational performance via cutting-edge strategic planning and programs. A results driven leader with excellent communication & motivation skills, creative thinker, innovative problem solver, strong in outsource manufacturing and excellent track record in start-up and turnaround situations. Achieving operations excellence thru LEAN manufacturing and supply chain.

Language Skills

Language Proficiency
Hindi He is very proficient in Hindi (an Indian Language).
Kannada He is very proficient in Kannada (an Indian Language)
Tamil He can speak proficiently in Tamil

Fields of Expertise

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