Machine-making savings
Documented total capital saving across six machine entries.
Available for international opportunities
Production management · Industrial engineering
Engineering production systems that perform.
Moniruzzaman Mia is a production management engineer focused on machine development, process optimization, capacity improvement and measurable manufacturing results.
$52.5K machine savings$59.1K/yr Six Sigma savings
SYSTEM / 01PROCESS STABLE
01 / IMPACT
Results, not adjectives.
Every headline figure below comes directly from the existing portfolio’s project records.
Six Sigma savings
Combined annual saving across three documented projects.
Machine entries
Designed or manufactured machine solutions recorded from 2018–2024.
Best defect reduction
Middle cross scratch reduced from 1.20% to 0.00%.
02 / ENGINEERING PHILOSOPHY
From constraint to controlled process.
A hands-on engineering leader who connects production data with practical shop-floor execution. His documented work spans purpose-built machinery, Lean and Six Sigma improvement, defect reduction, faster changeovers, KPI analysis, technical investment evaluation, and team leadership.
“Measure the constraint, design for the operator, verify the result, and standardize what works.”
Manufacturing leadership
Production management, capacity planning, workforce coordination and continuous improvement.
Engineering investment
Machine technical evaluation, technical justification, SRM investment and tool-shop investment workflows in SAP.
Performance systems
Factory A3 reporting across productivity, production, sustainability and quality indicators.
03 / CAPABILITIES
Engineering across the production system.
Capabilities are grounded in documented projects, responsibilities and training.
FLOW / 06 NODES
Production systems
Capacity analysis, production planning, resource allocation, OEE and KPI review.
Machine development
Technical evaluation, mechanical specification, fabrication oversight and operator-focused implementation.
Lean improvement
Kaizen, SMED, process-time reduction, waste elimination and standardization.
Six Sigma
Structured defect and scrap reduction with quantified annual savings.
Operational leadership
Manufacturing management, team leadership, training and cross-functional project delivery.
Investment control
SAP-related technical evaluation, justification, SRM investment, tool-shop investment and shopping-cart workflows.
04 / SELECTED WORK
Engineering case studies.
Problems, interventions and outcomes—structured for fast review by engineering and production leaders.
Capacity engineering · Six Sigma
Body Foaming Capacity Increase
Reduced cycle constraints in the body-foaming section through targeted mechanical and drive-system changes.
BDT 177KImplementation costSource value: BDT 1,77,000 (€1,727).
BDT 11M/yrDocumented savingSource value: €107.50K per year.
4Mechanical interventionsPulley, gear ratio, sprocket and inverter speed.
Constraint
Increase production capacity by decreasing cycle time in the body-foaming operation.
Engineering response
- Changed the pulley affecting body-in trolley time.
- Changed the gear-motor ratio for jig-to-trolley transfer.
- Changed the 16-piece chain sprocket affecting jig travel.
- Increased body-out trolley speed through inverter adjustment.
Verified outcome
The documented investment was BDT 177,000 (€1,727), with stated savings of BDT 11 million per year (€107.50K).
Machine development · Capital optimization · 2018–2024
Purpose-Built Production Machines
A documented portfolio of factory-built equipment for condenser, evaporator, tube-flaring and cabinet-trimming operations.
$52,500Total documented savingCombined source-table total.
6Machine entriesIncluding three automatic condenser bending machines in one entry.
2018–24Recorded yearsYears present in the project data.
Constraint
Meet production needs with fit-for-purpose machinery while reducing external purchasing cost.
Engineering response
- Built condenser straightening and cutting capability for coated MS tube.
- Developed condenser bending with tension straightening and a safety mechanism.
- Built a semi-automatic evaporator pressing and pasting machine.
- Developed tube flaring and later cabinet-trimming solutions.
Verified outcome
The source records six machine entries and a combined estimated saving of $52,500.
Kaizen · Six Sigma
Defect & Scrap Reduction
Applied focused countermeasures and structured improvement methods to reduce visible defects, damage and material scrap.
100%Best recorded reductionMiddle cross scratch: 1.20% to 0.00%.
$59,121/yrSix Sigma savingsCombined source-table total.
3Kaizen countermeasuresProtector, working table and fabric covering.
Constraint
Reduce recurrent surface damage and high-cost production losses without obscuring the measured baseline.
Engineering response
- Introduced a protector to reduce body dents and scratches.
- Added a working table to eliminate middle cross scratches.
- Used fabric covering to reduce liner scratches.
- Ran separate Six Sigma projects for middle traverse scrap, PU foamed cabinet damage and door-cap scratches.
Verified outcome
Kaizen records show reductions of 73%, 100% and 67%. Three Six Sigma projects record $59,121 in combined annual savings.
05 / DATA ARCHIVE
The numbers behind the work.
Exact source values remain available in semantic tables; select a dataset to inspect it.
DELTA / VERIFIED
CAPEX / MACHINE DEVELOPMENTMachine-making savings$52,500 total
| Machine | Year | Qty | Build cost | Buy estimate | Saving |
|---|---|---|---|---|---|
| Condenser straightening and cutting machine | 2019 | 1 | Not recorded | Not recorded | Not recorded |
| Automatic condenser bending machine | 2019 | 3 | $16,000 | $48,000 | $32,000 |
| Flaring machine | 2019 | 1 | Not recorded | Not recorded | Not recorded |
| Evaporator press machine | 2018 | 1 | $9,000 | $14,500 | $5,500 |
| Cabinet trimming machine (FF — 3 models combined) | 2024 | 1 | $9,000 | $17,000 | $8,000 |
| Cabinet trimming machine (FRZ) | 2024 | 1 | $5,000 | $12,000 | $7,000 |
LEAN / PROCESS DEVELOPMENTProcess-time improvement2018–2023
| Year | Processes | Previous | Current | Saved | Saving |
|---|---|---|---|---|---|
| 2018 | 10 | 630s | 580s | 50s | 8% |
| 2019 | 5 | 255s | 232s | 23s | 9% |
| 2020 | 4 | 238s | 221s | 17s | 7% |
| 2021 | 6 | 354s | 305s | 49s | 14% |
| 2022 | 9 | 533s | 489s | 44s | 8% |
| 2023 | 10 | 593s | 502s | 91s | 15% |
KAIZEN / QUALITYDefect reductionUp to 100%
Body dent & scratchUse of protector
Before5.74%
After1.50%
Reduction73%
Middle cross scratchUse working table
Before1.20%
After0.00%
Reduction100%
Liner scratchCovering by fabric
Before1.50%
After0.50%
Reduction67%
SMED / CHANGEOVERMachine setup time25–38% faster
| Machine | Qty | Before | After | Saved | Saving |
|---|---|---|---|---|---|
| Mechanical power press machine | 3 | 37.6 min | 25.4 min | 12.2 min | 32% |
| Roll forming machine | 1 | 30.52 min | 18.95 min | 11.57 min | 38% |
| Thermoforming machine | 3 | 95.09 min | 71.7 min | 23.39 min | 25% |
SIX SIGMA / COSTAnnual project savings$59,121/year
| Project | Methodology | Annual saving |
|---|---|---|
| Middle traverse scrap reduction | Six Sigma | $34,658 |
| PU foamed cabinet damage reduction | Six Sigma | $20,063 |
| Door cap scratches reduction | Six Sigma | $4,400 |
| Documented total | $59,121 | |
06 / TRAINING
Credentials for disciplined improvement.
- 01Certified Lean Six Sigma Black Belt
- 02Certificate of Excellence — Leading People & Team
- 03Finance for Non-Finance Managers (FNM)
- 04ISO 45001:2018 Occupational Health & Safety
- 05Certified Refrigeration and Air Conditioning Assessor
- 06Technical Training on Refrigerators in China
- 07Certified KPI (Key Performance Indicator) Professional
07 / CONTACT
Have a production challenge worth solving?
Discuss an engineering role, manufacturing project, consulting need or professional collaboration directly with Moniruzzaman.