Shafi Khaja

• More than 15 years of Manufacturing Engineering, Projects Management and Customer relations experience. 
• Strong organizing, people, leadership, communication, and negotiation skills.
• Ability to address details, decisions making, work under pressure, meet tight deadlines, handle multiple tasks/responsibilities, work as an individual as well as a supportive team member. Self - starter and result oriented.
• Hands on experience in design and manufacturing of production equipment and automated assembly machines. (Mechanical, Hydraulics, Pneumatics, PLC and Electrical, Automated assembly lines) and implementation of continuous improvement plans.
• Computer skills: Strong Microsoft project, office and outlook, Power point presentations. Working knowledge of AutoCAD, Solid Works, and ERP.

Self Employed (April 2023 – Present)

• Managing private home renovation projects, while exploring a full-time permanent position in an industry related to my work experience.

AXIOM Group Inc., Aurora, Ontario, Canada.

Manufacturing Projects Manager (April 2022 – Dec 2022) 

• Managed a team of manufacturing and other company’s internal departments in successful launch of interior and exterior components projects for automotive OEMs (Stellantis, Rivian, Tesla, GM, Ford), meeting tight deadlines and awarded budget. Managed several current manufacturing work cells and assembly lines.
• Liaised with customers and provided support on various project management and manufacturing issues. Act as the key point of contact to the client’s program leader/technical counterpart. Ensured customers specific requirements related to product design, manufacturing and quality are identified and communicated internally and externally to achieve successful projects launch. Be accountable to keep customer and program on track with effective conflict resolution.
• Built overall project budget, compiled budget requests, and generated capitalization plan based on project timelines. Monitored and managed all project key dates and timelines. Facilitated program/project status meetings with project teams & account steering teams.
• Managed start up and optimization of the manufacturing processes and machines. Optimization of work cell layouts, cycle times and ergonomics. Worked closely with company’s internal departments in addressing customers concerns and manufacturing bottle necks. Managed process documentations, PPAP submissions and obtained customer approvals (Process sign offs and payments).
• Worked closely with suppliers to manage the successful completion of the awarded business (tooling, assembly fixtures and measuring gauges). Develop Requests for quotes, review quotations and initiate purchase requisitions.
• Assisted in the development of technical presentations to support the Sales team as well as lead or assist with technical reviews for programs related to engineered solutions and preparations of quotes.
• Developed requisitions for capital equipment, tooling and required material for the assigned projects.
• Completed product and equipment design reviews and provided approvals for manufacturing. Worked closely with company’s internal departments in optimizing manufacturing processes, work cell layouts and cycle times, ergonomics, and line balancing.
• Assisted internal teams for preparation of proposals, business plans, proposal work statements & specifications, operating budgets, and financial terms/conditions of contract. Ensured compliance of IATF-16949 systems and procedures. Assisted with Continuous Improvement Initiatives for current systems and processes.  

Pro Design Solutions Inc., Toronto, Ontario, Canada.

Senior Manufacturing and Plant Engineer. (Dec. 2018 – Jan 2022)

• Provided manufacturing engineering support to company’s internal departments in launching of new products and managing of current production work cells and equipment. Developed tooling, assembly lines and product quality check fixtures required for new products launch.
• Provided engineering quote inputs related to equipment and resources requirements for a successful project launch. Successfully converted several manual assembly lines to semi automated, resulting in increased productivity and labor reduction. Developed quick change over processes and manufacturing cells.
• Successfully implemented one piece flow concept by re-organizing workflow layout and line balancing, resulting in WIP and multiple handling elimination/reduction.
• Led and managed a team of junior process engineers, production supervisors and line operators in launching of new project and achieving daily production targets and product quality.
• Reviewed and approved products and equipment design, manufacturing processes and quality standards.
• Reviewed quoted production cycle times, productivity, labor efficiencies and worked towards improvements. Resolved production bottle necks and worked on continues improvements. Worked closely with company’s internal departments to address and resolve customer concerns related to product quality and performance.
• Review subcontractors’ quotes and issue purchase orders. Supervise outsourced work (timing and budget).
• Successfully managed the installation and start up of several CNC Panel and Profile Cutting machines. 
• Managed a team of technicians in the daily maintenance of production machines and plant equipment. Supervised preventive and breakdown maintenance activities. Issued and followed up on maintenance work orders. 
• Conducted engineering and maintenance staff performance reviews and provided feedback. Led daily and weekly projects launch and operations meetings.
• Reviewed and implemented continuous improvement opportunities (improvements in productivity/labor efficiency, cycle times, automation, 5S).
• Increased the overall machines efficiency by 20% by troubleshooting functional issues. Reduced scrap by 10% on 2 tile cutting work cells, improved process flow by re-structuring punching operations cell. 
• Successfully launched several new production and assembly lines.

Jan 2018 – Aug. 2018.

• Took time off to visit India to take care of a pending family matter. During the stay, worked volunteering on a plastic scrap recycling project, converting scrap into granules for processing.

ABC Group Inc., Brampton, Ontario. Canada.

Senior Projects/Manufacturing Engineer (Sep. 2015 – Dec. 2017)

• Successfully launched several automotive components manufacturing and assembly projects involving fully and semi automated work cells, budgeting from 2 to 4 million dollars (Chrysler Ram Box, General Motor fascia programs to mention as few examples). Managed customers and suppliers’ timelines, budget summaries, KOIs and APQP. Worked closely with Production and Quality departments in managing daily manufacturing activities and meeting end products quality requirements.
• Worked closely with the designers in the development and completion of DS RAM Box concept.
• Supported Chrysler and General Motors lead Engineers throughout the program launch in understanding and communicating the scope of the project. Addressed and resolved customers concerns.
• Supervised a team of junior engineers and plant personnel by assigning responsibilities and following up on implementation (tooling trials, prototype builds, process optimization, assembly cell layouts, work instructions, FMEA, control plans, engineering changes, operator training, run rates completion, customers sign off).
• Worked closely with sales in quoting new business by providing project feasibility studies and quote inputs (scope of work, product specific requirements, manufacturing feasibility, resources and equipment requirement, process parameters).
• Managed subcontractors and suppliers (request for quotes, purchase orders, timelines, tooling and equipment build, automation).  
• Continuous improvement. Addressed warranty issues by eliminating lock interference issue resulting in cost saving of $60, 000. Reduced scrap on GM glove box from 6% to 2% by resolving pin misalignment issue.

Metform International Inc., Mississauga, Ontario.

Projects Manager (Manufacturing) – (June 2010 – Aug 2015)

• Successfully launched several roll-forming (tooling and mills) automotive and commercial projects, budgeting from 2 to 7 million dollars, meeting budgets and timing. 
• Managed global customers and suppliers. Understood and communicated customer requirements related to quality, timing, and budget to the company’s internal departments. Ensured customer specific requirements are met and implemented at all phases of the project. Ensured accurate communication is maintained throughout the program launch. Provided technical and engineering support to the customers and suppliers. Reviewed quotes and issued Purchase orders. Conducted tooling try-outs and provided buy off. 
• Handled technical and commercial aspects of each project. Assisted Sales in quoting new business. Managed Engineering changes. Followed up on the payments schedule and timing. 
• Developed and followed up project timelines. Participated in design reviews and obtained customers’ approval for manufacturing. Supervised machines and tooling tryouts. Developed machine/tooling approval documents and obtain customers buy off for final shipment. 
• Coordinated onsite tooling/equipment commissioning and obtained customers final approvals. Managed warranty issues.

Bachelor of Mechanical Engineering 

Certificate Courses: Injection Molding, Team oriented problem solving (8D), GD&T, PFMEA, Advance Product Quality Planning (APQP), Design of Experiments, Problem Resolution Process, Industrial Ergonomics, Workplace Health and Safety. Solid Works.