Syed Ameer Hasan

About the Candidate

Results-driven Manufacturing/Process Improvement Professional with 10+ years of expertise in Lean Six Sigma methodologies, cross-functional team leadership, and ISO-compliant process optimization. Proven track record in reducing production costs by 10–20%, improving on-time delivery to 98%, and driving continuous improvement in OEM automotive and heavy manufacturing sectors. Adept at Value Engineering, Cost Analysis, and deploying Lean tools to enhance safety, quality, and operational efficiency. Certified in Industrial Automation & Process Optimization with hands-on experience in global project execution and supplier collaboration

WORK EXPERIENCE
March’23 – March’25 as Manufacturing Engineer at NAFFCO FZCO (Trucks & Vehicles) , Dubai
Key Result Areas:
 Led cross-functional teams of 30+ technicians to optimize sheet metal chassis production, achieving 98% on-time delivery through Lean workflows and resource reallocation.
 Spearheaded Value Engineering initiatives, redesigning 5+ components to reduce production costs by 10% while maintaining ISO 9001/IATF 16949 compliance.
 Conducted Six Sigma root-cause analysis to eliminate production bottlenecks, ensuring zero non-conformance during audits.
 Acted as liaison between design, procurement, and shop-floor teams, reducing rework by 15% via streamlined workflows
May’21 – Feb’ 23 as Manufacturing Engineer (Process Improvement) at Metal Seam Company Pvt Ltd , Lucknow
Key Result Areas:
 Redesigned 4+ sheet metal fabrication processes using PDCA and low-cost automation, boosting output by 18% and cutting cycle time by 20%.
 Achieved BIS certification (IS 2552:1989) by aligning drum manufacturing with AS9100-like standards, reducing defects by 18%.
 Managed 5+ fabrication projects, delivering 100% on-schedule with 10% cost savings via optimized material usage.
Jun’18 – Jun’20 as Maintenance Engineer at Plasco Factory for Plastic Industries, Riyadh Saudi Arabia
Key Result Areas:
 Executed preventive maintenance strategies, increasing production uptime to 95% and reducing MTTR by 18%.
 Installed and optimized new equipment, ensuring seamless integration into production workflows.
Jul’14-May’18 as Production Engineer at Gloria Engineering Company, Lucknow
Key Result Areas:
 Slashed welding defects by 40% through Poka-Yoke integration and 5S workplace organization.
 Reduced sheet metal waste by 15% via Lean-driven nesting optimization.
PROJECTS
Value Engineering: Chassis Manufacturing Optimization | NAFFCO FZCO
 Delivered 60 chassis/year with minimal rework using Lean methodologies, saving AED 250K annually.
Lean Six Sigma: Drum Assembly Line Cycle Time Reduction | Metal Seam Company
 Reduced changeover time by 25% through PDCA and automation, achieving 15% cost savings
Quality Improvement: Welding Fixture Validation | Gloria Engineering
 Cut quality losses from 700 ppm to <100 ppm via fixture redesign, achieving Zero PPM targets.
TECHNICAL SKILLS
 Process Tools: Lean Six Sigma, Value Engineering, PDCA, 5S, Kaizen, Poka-Yoke, FMEA
 Software: MS Office, AutoCAD, SAP (Basics), Data Analysis (MTBF/MTTR)
 Standards: ISO 9001, IATF 16949, AS9100, BIS/IS 2552
ACADEMIC DETAILS & CERTIFICATIONS
 Industrial Automation & Process Optimization | Sofcon India Pvt Ltd | 2020–2021 (PLC, SCADA, Hydraulic & Pneumatic Systems, )
 B.Tech (Mechanical Engineering) | B.N College of Engineering & Technology, Lucknow | 69.14% | 2014
 12th & 10th | St. Xavier’s Public Inter College, Lucknow | 74.5% & 67.16%
LANGUAGES
 English (Professional), Hindi (Native)