Dhrumil Vaghela E.
Manufacturing Engineer @CoolIT Systems
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WORK HISTORY
Manufacturing Engineer @CoolIT Systems
Calgary, AB, CA
Developed, implemented, and continuously improved manufacturing processes, standard work, and process documentation with a strong focus on waste (muda) elimination- Designed assembly and sub-assembly process flows and created detailed Process Flow Diagrams (PFDs) to support efficient and repeatable operations- Performed Value Stream Mapping (current and future state) to identify bottlenecks, reduce lead time, and improve overall process flow- Implemented Kanban systems to enable controlled production, reduce WIP, and support pull-based manufacturing- Conducted workload leveling (Heijunka) and line balancing to stabilize production output and optimize labor utilization- Designed, modified, and optimized facility, work-cell, and workstation layouts, including greenfield layouts, using 5S and systematic layout planning- Identified point-of-use (POU) equipment requirements to improve material flow, operator efficiency, and ergonomics- Identified and implemented autonomation (Jidoka) requirements, including design, verification, and validation of automated and semi-automated processes- Designed and implemented jigs, fixtures, and poka-yoke solutions to improve process capability, quality, and repeatability- Designed ergonomic workstations, tables, and support structures to enhance operator safety and productivity- Developed and maintained PFMEA, identified CTQ processes, and reduced RPN through risk mitigation and process improvements- Led 8D problem-solving and other structured quality initiatives to address root causes and prevent recurrence- Performed sub-optimization and impact studies to evaluate proposed changes, identify downstream effects, and ensure sustainable improvements.
EDUCATION
University of Calgary
Master's degree, Mechanical and manufacturing engineering
B and B Institute of Technology,Vallabh Vidhyanagar - GIA 604
Diploma, Mechanical Engineering, 8.9 GCPA
G H Patel College of Engineering & Technology
Bachelor of Engineering - BE, Mechanical Engineering, 3.82 GPA
ABOUT DHRUMIL VAGHELA E.
Why work hard when you can work lean?”I am a Manufacturing Engineer with a strong foundation in Quality Engineering and Lean Manufacturing, focused on designing efficient, scalable, and quality-driven production systems. My career spans process engineering, facility and work-cell design, autonomation (Jidoka), quality systems, and people leadership, all anchored in waste elimination and continuous improvement.Currently, my work involves- Developing and improving manufacturing processes, standard work, and documentation- Designing assembly and sub-assembly lines, Process Flow Diagrams (PFDs), and optimized facility/work-cell layouts- Applying Lean tools such as Value Stream Mapping, Kanban, Heijunka, 5S, and poka-yoke- Leading PFMEA, CTQ identification, RPN reduction, and 8D problem-solving- Performing sub-optimization and impact studies to ensure changes deliver system-wide benefits.Earlier in my career, I spent 4 years as a Quality Technician at a global manufacturer of hygienic stainless-steel process valves. During this time, I- Introduced the Quality Circle concept, driving cross-functional collaboration that reduced rejection rates and unnecessary material movement- Designed inspection gauges and fixtures (Go/No-Go, plug gauges) to improve inspection accuracy, speed, and manufacturing efficiency- Trained operators on critical dimension inspection, GD & T interpretation, and machine parameter adjustments, significantly reducing rework-Implemented Lean and Kaizen-based layout improvements, achieving a 12% production rate increase within the first monthI also bring hands-on operations leadership experience, having managed one of the largest departments at Real Canadian Wholesale Club, leading a team of 20 associates. By applying time and motion studies and Lean thinking, I improved productivity by 40% within the first week, while developing people, balancing workloads, and linking daily tasks to business performance.My experience in technical sales further enables me to bridge engineering, operations, and customer value. I am driven by one goal: to build manufacturing systems with minimal waste, strong quality foundations, and maximum human potential—and, in the long term, to translate this expertise into a Lean material handling and manufacturing consulting practice.Always open to meaningful conversations and opportunities in Manufacturing Engineering, Lean, and Continuous Improvement.
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