Amir Marvi

Amir M. Marvi

3131 Southbrook Ct. # 211, Manitowoc, WI 54220 •Tel. #: (309) 231-1734
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Lead Manufacturing Engineer with over 25 years of success in heavy equipment and consumer goods manufacturing Industries, with Bachelor of Science and Master of Engineering degrees in the field of Mechanical Engineering. Demonstrated ability to implement engineering solutions in a LEAN Manufacturing environment. Certified in Six Sigma Black Belt, CPS (Caterpillar Production System) Black Belt specializing in application of LEAN Manufacturing methodologies, Industrial Engineering, and New Product Introduction. Proven record of achievement in introducing improved material handling and production methods, cost reduction and increasing productivity performance. Proficient with 3D CAD, and Microsoft Office applications. Experienced with hydraulic/electrical control systems. Problem solving methods. Recognized leader and mentor to less experienced engineers.
Additional Strengths & Competencies
• Tooling / Fixture Design Processes/ Gear Mfg. • Value Stream Mapping • Kanban/ Value Stream Transformation
• MS Word, Excel, Power Point • Problem Solving Standardized Work • New Automation/ and Equipment Acquisitions
• Six Sigma tools, Kaizen Events, LEAN Tools • Advanced Manufacturing Engineering in Fabrication & Assembly Systems • 3D Modeling / Factory CAD / Solid Works

Kohler Company, April 2015 to June 2015
Manufacturing Engineer (Short Term Contract Assignment)
Kohler Engines Division, Kohler, Wisconsin
Job Responsibilities & Key Accomplishments:
• Development of facility layouts, manufacturing process steps for fabrication and assembly of new engines. Implementation of Productivity, quality and safety improvements in the existing manufacturing processes.
Broadwind Towers & Heavy Industries, Sept. 2014 to April 2015
Sr. Manufacturing Engineer, Manitowoc, WI
Job Responsibilities & Key Accomplishments:
• Development of facility layouts, manufacturing process steps and preparation of proposals for
• New custom made systems and products.
• Implementation of productivity improvements in the wind towers manufacturing processes through utilization of LEAN Manufacturing principals.
• Productivity improvements through introduction of alternate welding and fastening methods and utilization of Six Sigma methodology.
• Design of equipment and machinery utilizing Auto/CAD and SoildWorks. Page 1 of 5

• Prepared Work Instructions, and the Sequence of Events (SOE) for new jobs.
• Worked closely with the process owners and the production support teams to collect inputs, and commitments for a realistic and achievable project plan.
John Deere Company, Jan. 2013 to June 2014
PDP Weld Engineer, Air Seeding Group, Valley City, North Dakota
Job Responsibilities & Key Accomplishments:
• Planning and execution of NPI (New Product Introduction) in the area of Weld fabrication as a lead Product Delivery Process (PDP) Weld Engineer.
• Responsible for construction and detailing and implementation plan for the weld tooling, weld gear, and automation to launch a new Air Seeding product program on time and within budget.
• Define the Sequence of Events (SOE) and build process for all in-house welded assemblies as a LEAN Manufacturing Engineering SME (Subject Matter Expert).
• Concurrent NPI (New Product Introduction) and product development with Design, Quality, Marketing and Finance teams.
• Utilized FEA analysis for review of design concepts, and conducted suitability for manufacturability, cost effectiveness, productivity and safety evaluation.
• Used cProjects for labor and processing cost calculations.
• Conducted Virtual Build events with cross functional teams. Validated new manufacturing processes.
• Participated in fabrication and testing of prototype weldments, functional build reviews at suppliers.
• Developed design concepts for weld tooling, fixtures, robotics, automation, and material handling designs.
Caterpillar, Inc., 2008 to 2012
Senior Manufacturing Engineer & Lean mfg. Leader – Peoria-Illinois
Virtual Manufacturing Engineering.
Job Responsibilities & Key Accomplishments:
• Implementation of Lean Mfg. principles / Caterpillar Production System (CPS) in processes associated with heavy machinery production, as a LEAN Manufacturing Engineer Subject Matter Expert (SME).
• Improved productivity through utilization of Value Stream Transformation (VST) work in the gear casting and gear machining/fabrication area.
• Developed, analyzed and validated 3D layout models for new production and manufacturing operations through utilization of Virtual manufacturing engineering solutions. Documented the best practices guidelines and procedures for factory design & modifications. Collected 3D factory data and created shop floor models.
Trane, Inc. (An Ingersoll-Rand Company) 2005 to 2008
Six Sigma Black Belt & Value Stream Leader –Columbia, SC
Job Responsibilities & Key Accomplishments:
• Directed the plant-wide LEAN initiative by getting involved with defining the current and future state Value Stream Map to plan and prioritize Continuous Improvement activities. Page 2 of 5

• Implemented Six Sigma Black Belt projects and led five value streams from raw materials to finished goods in the heat exchanger (coils) manufacturing plant.
• Conducted gauge R&R, capability (Cp & Cpk) studies on equipment, in-process inspection of components and assemblies, data tracking, root cause analysis for in-house and customer issued corrective actions.
• Participated in Kaizen Events, Standardized Work, Takt Time analysis, Work Place Organization, Visual Management, Kanban, Build-in Quality and TPM (Total Productive Maintenance) activities.
• Improved braze processes by updating and documenting braze and weld procedure specification.
• Achieved plant certification for brazing and pressure retaining processes as a part of Canadian Registration Number (CRN).
• Reduced copper tubing scrap by 50% and improved assembly productivity with savings of $375K/yr.
• Designed software and implemented WinSPC in the fabrication areas that resulted in scrap avoidance of $280K/yr.
• Achieved 20% unplanned downtime reduction on fin press through TPM event.

Bosch/Siemens Home Appliances Corporation 2000 to 2004
Six Sigma Black Belt (2002 to 2004) – New Bern, NC
Senior Process Engineer (2000 to 2002)
Job Responsibilities & Key Accomplishments:
• Managed new tooling including evaluation of design specifications, justification, vendor selection, acquisition, installation, proofing and operation for manufacturing of transmission components and fabrication/machining of gears.
• Coordinated Lean implementation and activities such as material conveyance, problem solving, standardized work, set-up reduction, 5S, visual work place and error proofing.
• Provided daily manufacturing engineering support in the sheet metal fabrication and gear manufacturing areas. .
• Saved $150K/year by reducing the dishwasher wiring related defects and rework by following DMAIC methodology with a cross-functional team approach.
• Saved $400K/year through reduction of dishwasher tub material thickness.
• Improved productivity of the automated panel-forming machine by removing the downtime reasons that eliminated one shift of operation with $70K/year labor savings and overtime avoidance.
• Managed rebuilding and installation of the tub expander tooling without any production interruption, which avoided scrap due to splits with $80K/year savings.
• Utilized SMED tool that reduced the hydraulic press set up and changeover time by 20%.
• Put in place work instructions and visual management in the assembly area that reduced operator errors resulting in 75% rework reduction.
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Whirlpool Corporation 1994 to 2000
Six Sigma Black Belt (1997 to 2000) –Marion, OH
Senior Process Engineer (1994 to 1996)
Job Responsibilities & Key Accomplishments:
• Implemented Six Sigma Black Belt, LEAN Manufacturing and productivity improvement projects as a part of Operational Excellence Program that improved margins and profitability, and managed capital investment projects.
• Reduced dryer lint alert’s field service calls by 80% with savings of $120K/year.
• Led Kaizen events on two automated panel lines that improved the critical process yield by 25% per line.
• Utilized Kanban system that increased floor space on high-volume assembly lines, improved productivity and reduced changeover time by 15%.
• Managed and implemented addition of a new $750K assembly line for production of the Mini dryer on time and within budget as part of production transition from Canada to US.
• Increased the uptime of two packaging machines by 10% through establishment of SOP (Standard Operating Procedures).
• Identified $1.5M/year savings for the dryer plant in France as a part of the Global Leverage project.
• Integrated two new console sub-assembly carousels with productivity improvement of $140K/year.
Speed Queen Company 1990 to 1994
Senior Corporate Project Engineer-Ripon, WI
Job Responsibilities & Key Accomplishments:
Provided capital investment, project management and implementation in the washer plant. Developed corporate engineering specifications for new tooling and equipment acquisitions. Participated in simultaneous engineering to assure manufacturability and cost effectiveness. Contributed to the successful implementation of a $40M capital investment factory upgrade project and introduction of the next generation washer product on time and within budget. Managed the implementation of a new multi-million dollar automated washer cabinet line that eliminated one shift of operation and reduced labor, material cost reduction, increased productivity through automation with savings of $450K/year. Managed addition of a new washer front panel tooling with a tooling investment of $400K. Achieved 15% production capacity increase by adding automation and coil feeders to two mechanical presses. Relocated the mechanical press line with 20% productivity improvement. Reduced the washer transmission’s field service call rate by 60% by enhancing the aluminum casting and machine shop processes and procedures. Improved processes in the gear machining operations.
General Electric Company, Process Control Engineer- Refrigerator Plant- Louisville, KY- 1988-1990
Parker Metal Stamping Company, Inside Sales & Production Engineer – Cincinnati, OH -1986-1988
Roll Forming Corporation, Computer Aided Design Intern- Shelbyville, KY-1984-1985
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Bachelor of Science and Master of Science degrees in Mechanical Engineering from University of Louisville, LEAN Mfg. Subject Matter Expert (SME), Caterpillar Production Systems’ Black Belt, certified Six Sigma Black Belt.
Technical Skills: Project Management (cradle to grave), Equipment/Machine specifications and reliability, Mechanical systems, Process improvements, Industrial Engineering. DMAIC. VOC. CTQ. Process failure mode and effects analysis (PFMEA) utilizing manufacturing as a process; implementation of mistake proofing, Design & Process FMEA. Poka-Yoke. DOE. SPC. WinSPC. ISO. TPM. JIT. TQC. DFM. DFA. 8D. 5 Why. 5S. Value Stream Mapping. Kaizen events. Kanban. SMED. Mechanical design. Robust design. Concurrent Engineering. Finite Element Analysis (FEA). Time study. Capacity planning. Trouble shooting. Root cause analysis. Writing specifications. Work instructions and procedures. Safety & Ergonomics. Quality instrumentation. Visual management. GD&T. Maximizing work flow and floor space layouts. •Experience with metrology and coordinate measuring machines (CMM).
Manufacturing Process Skills: Sheet metal fabrication. Assembly and sub-assembly. Automation. Robotics. Tool and die. Pressroom equipments and processes. Machine shop equipments and processes. CNC. Heavy fabrication. Casting. Gear manufacturing. Tube bending. Welding. Brazing. Quick changeover. Material handling system. Injection & blow molding of plastics. Hydraulics & pneumatics. Heat treatment. Induction hardening. Annealing. Ferrous metallurgy. Process/product development. New product launch. Fastening systems. Sourcing of new equipment and tooling. NPI (New Product Introduction). Supplier quality. Supply chain management. Work place organization. Quality inspection. Advanced Part Quality Planning (APQP). Ability to work collaboratively with multiple levels in the organization
Software Skills: Computer literate and proficiency with Microsoft office (Word, Excel, Power Point and MS Projects). Visio. CAD/CAM. AutoCAD. Pro/E solid modeling. SolidWorks. Teamcenter. Siemens PLM. FactoryCAD. FactoryFLOW. Minitab. JMP. WinSPC. Lotus Notes. SAP. Pareto charts. Gantt charts. VisMockup. VisJack.
Technical & Business Trainings: Transitioning to Management. Project Management. Six Sigma Black Belt. Six Sigma Green Belt. FMEA. DOE. WinSPC. ISO, EVA (Economic Value Added Analysis). Product safety. Ergonomics. Robot programming. PLC.
Personal: Married with one child, home owner, US Citizen.
References: available upon request.

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  • Updated 7 years ago

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