LOKANADH SASANK PRABHALA

WORK EXPERIENCE

Operations Engineer, Amazon.com
Ottawa, ON, Canada • Jan 2020 — May 2022

• Led teams (75+ crew) to execute complex material handling, sortation systems and Amazon robotics projects at YOW3 (Ottawa), YOO1 (Ajax), and YHM1 (Hamilton) achieving project milestones.
• Participated in engineering reviews, identified and rectified defects in the layout design of YOW3 inbound process, resulting in cost savings of $86.37k.
• Implemented quality control plans (ex: acceptance sampling) to ensure material delivered compliance with specifications and standards, resulting in a 95% reduction in non-conformances.
• Conducted a thorough 5Why analysis to identify the root cause of the malfunction in the YHM1 Shipping sortation system and successfully executed solutions to meet the Amazon standards of Six Sigma quality.
• Demonstrated strong analytical and project management skills by implementing Plan-Do-Check-Act (PDCA) cycles, resulting in a significant 15% reduction in installation defects.
• Monitored Project critical path activities to mitigate risks and hired sub-contractors to accomplish installation targets as needed. 

Continuous Improvement lead, Pink Zebra Home LLC

Houston, TX, USA • June 2018 — Dec 2019

• Optimized Order Picking and Packing systems of warehouse by performing time studies to measure KPI's; induced ergonomics changes in workstations to decrease wasteful process that saved 5min/ hour/ station.
• Implemented a comprehensive inventory cycle counting program that was carried out quarterly, resulting in a substantial reduction in inventory losses from $84,000 to $6,000 within one year. 
• Presented a business case to higher management illustrating the ROI of automating jar, pouch, and container filling processes and got approved.
• Installed automated 5-station Horizontal (1oz) Pre-made pouch packing, Jar (8 oz) and (16oz) container filling machinery to escalate production rate by 225% and lowered build time by 85%. Decreased production cost per unit from 16.5 cents to 4.55 cents.
• Mentored 6 Supervisors to implement continuous improvement activities like Kaizen Blitz, DMAIC, and 5S+1 to reduce average Jar manufacturing cycle time by 6 min per 100 count.
• Reviewed, standardized, and documented manufacturing operation procedures to meet ISO 9001:2015 guidelines. Established Excel data sheets to monitor WIP inventory using Vlookups, data tables, & pivot Charts.

Industrial Engineer, Bharat Electronics Ltd

IND • March 2014 — Dec 2015

• Led cross-functional team of 10 members to deliver a production order of 3000 specimens worth $60M on the Project “Site T 72’ (a thermal imager, Electro-Mechanical/optical device).
• Revamped optical assembly workstations by incorporating Methods-Time Measurement (MTM), resulting in a remarkable 22% increase in yield.
• Reconfigured inventory layout and storage rack locations using ABC analysis of high priority fast moving SKUs resulting in 16% growth in inventory utilization efficiency.
• Performed Failure Mode and Effects Analysis (FMEA) to proactively identify and mitigate potential failures, resulting in a 75% reduction in defects and improved product reliability.

INTERNSHIPS

Industrial Process Engineer, Formtex Plastic corp., Houston, TX, USA                            March 2018 – May 2018

Industrial Engineer, SLV Engineering Ltd(3PL)., India
January 2013 – March 2014

 

Knowledgeable in application of Quality Management Systems and ISO 9001 standards;

Expert in implementation of continuous improvement processes and tools such as: Six Sigma, FMEA, 8D, 5 Whys, Kaizen, PDCA, etc.

Developed and deployed quality control plans that ensure compliance to all specifications and standards