Saad Mirza
Mechanical Engineer from University of Waterloo – MBA Candidate at Quantic linkedin.com/in/1saadmirza
+ Extensive application of lean manufacturing principles at Tesla, Apple, Honda, and GM
+ Proven management skills honed in large scale, fast-paced manufacturing environments
+ Excellent hands-on experience from commissioning of testing rigs and vision systems
+ Certified Ergonomic Specialist (CES) and Basic MOST Applicator
+ Skilled in: SolidWorks, CATIA, NX, AutoCAD, Navisworks, 3DEXPERIENCE, Simul8, Autodesk Factory Design Suite, and Tableau
EMPLOYMENT
Manufacturing Industrial Engineer
Honda of Canada Manufacturing, Alliston, ON		Jul. 2019 – Present
+ Identified inefficiencies in double handling of materials delivered to the production line and presented solutions to optimize storage footprint, improve asset tracking, and map out best travel routes
+ Created factory space usage analysis to pinpoint areas for conversion to production space without investment in building expansion and used this data for make vs buy analyses of sub-assemblies
+ Designed plant layouts in AutoCAD for a new automated line, floor plan for equipment relocation to supplier site, and a complete outsource option
+ Currently completing a process by process comparison of multiple Honda models to formulate an equipment and material flow plan for a multi-model production line along with discrete event simulations
Manufacturing Engineer II
Tesla Inc., Buffalo, NY		Jul. 2018 – Mar. 2019
+ Led the floor layout design of Tesla’s entire operation in Gigafactory 2 including the solar roof line, future production lines, and Panasonic’s short-term ad-hoc needs
+ Overhauled the raw material flow to a Kanban system for just in time delivery to production lines and created heatmaps to recognize and eliminate areas of high traffic congestion
+ Designed process flows for a future line including creation of PFMEA, VSM, DFA recommendations, and redesigned existing assembly work station layouts to improve cycle time and ergonomics
+ Created a Plan for Every Part (PFEP) from five different product line BOMs and supplier part data to set up accurate lineside, repack, kitting, warehouse storage capacity metrics, MES, and MRP systems
+ Sourced conveyance systems from external suppliers for automated movement of WIP between stations
Industrial Engineer I
Tesla Inc., Sparks, NV		Nov. 2016 – Jun. 2018
+ Managed the design and layout of over 1.5 million square feet of Gigafactory 1 manufacturing space for Model 3 and Tesla Energy Products
+ Designed automated material handling solutions for the energy product lines to mitigate effects of downtime on throughput, and reduce material flow headcount costs by $4.7 million annually
+ Drove implementation of layout changes by working with construction, manufacturing, design, and production teams to meet aggressive timelines
+ Made high impact decisions on manufacturing line moves and install dates, and delivered recommendations to company leadership for approval
+ Developed the Manufacturing Building Information Model (BIM) to alleviate clashes between production lines, building, and material flow design
iPhone Operations Program Manager (Co-op)
Apple Inc., Cupertino, CA		Sep. – Dec. 2015
+ Created an equipment quantity calculator to identify areas of potential cost savings on the surface-mount technology (SMT) test line based on a seven-factor criteria
+ Analyzed production data to formalize a plan for a 70% reduction in rework and repair equipment required for a future product
+ Identified $25 million in savings by proving each line had additional unused capacity, and equipment usage and scrap rate was lower than what the contract manufacturer (CM) had communicated
Mechanical Engineering (Co-op)
Honda Engineering North America, Alliston, ON		Jan. – Apr. 2015
+ Designed a new method to use laser vision, reducing the cost of a process by 96% on the CR-V roof assembly line
+ Simulated side panel spot welding processes in DELMIA to determine changes required on set jig templates, clamps, and rough guides for new product introduction (NPI)
+ Piloted the use of 2-D vision systems for Fanuc and Motoman robots for rapid part identification to decrease cycle times
+ Established design specifications for new robot placements, weld gun changes, part presence indicators, and redistribution of weld points
Test Engineering Analyst (co-op)
Messier-Bugatti-Dowty, Ajax, ON			May. – Aug. 2014
+ Applied strain gauges on Dassault Falcon 7X landing gears to collect test data, and analyzed effects of fatigue and cyclical loading for verification of part durability
+ Tested Airbus A380 landing gear components using custom test rigs consisting of PID controllers, hydraulic actuators, torque motors, and servovalves
+ Developed a new method for calibration of thermocouples, pressure transducers, and load cells to automate and expedite the process, and improve repeatability
Manufacturing Engineering (Co-op)
General Motors of Canada Ltd., St. Catharines, ON				Sep. – Dec. 2013
+ Converted the valve body machining line process from serial to parallel to improve cycle times by 8%
+ Programmed and tested all transmission line CNC machines for physical tool breakage checks
+ Designed a handheld gauge for assembly plant to conduct additional leak tests prior to shipment
+ Implemented a new fixture to incorporate part transfer using an existing six-axis robot, resulting in reduced operator fatigue and improved ergonomics
Engineering Coordinator (Co-op)
Wheelabrator Group, Burlington, ON	May. – Aug. 2012 & Jan. – Apr. 2013
+ Designed a support structure in 3D, using Autodesk Inventor, for a multimillion dollar air blast machine
+ Conducted FEA analysis on structures and work hooks to establish the factor of safety for manufacturing + Modified the hanger bearing design to change assembly methods, and reduce failures
EDUCATION
Master of Business Administration (MBA)
Quantic School of Business and Technology				Expected Completion in 2021
Bachelor of Applied Science (BASc) Honours Mechanical Engineering – Co-op Program
University of Waterloo, Waterloo, ON	Sep. 2011 –  Apr. 2016
+ 4^th Year Capstone Project: Designed and prototyped an automated drone battery swap station in a team of four. Used sheet metal, 3D printing, linear actuators, solenoids, and a custom built X-Y table.
+ University of Waterloo Alternative Fuels Team (UWAFT): Designed and verified, through FEA, a mount for testing the EcoCAR 3 (2016 Chevrolet Camaro) motor on a dynamometer. Placed emphasis on DFM and DFA principles.