Fayaz Ali

About Fayaz Ali

I am a Mechanical Engineer and R&D professional with a Master’s in Autonomous Systems and Robotics from Illinois Institute of Technology. I specialize in translating R&D concepts into scalable, automated manufacturing processes, with proven success in reducing production costs by 70% and cycle times by 50%.My expertise bridges three key areas:1. Process Development & Automation: Scaling lab processes into production through integration of liquid handlers, robotics, and IoT controls.2. Mechanical Design & Simulation: Leveraging SolidWorks, CREO, and ANSYS for design, FEA, and rapid prototyping to de-risk development.3. End-to-End Project Leadership: Managing the full lifecycle from concept and validation to technology transfer and production training.I am passionate about building intelligent systems that enhance manufacturing efficiency and reliability. Open to connecting on innovative projects in R&D, automation, or advanced manufacturing.

Experience

1. Research and Development Engineer

   MilliporeSigma

   Jun 2025 — Present · Milwaukee, WI, US

   Led process development and scale-up for a new semi-automated production line, transitioning 5+ products from manual to automated workflows. Drove the project from R&D through customer validation to successful technology transfer, reducing cost of goods sold (COGS) by ~70% and manufacturing lead time by 50%.• Engineered and validated robust processes utilizing integrated lab automation (different liquid handlers), analytical instrumentation, and glovebox systems, ensuring product quality and reproducibility for sensitive chemical synthesis.• Owned the automation roadmap; designed and prototyped a secondary packaging system using CAD (SolidWorks) and rapid prototyping (3D Printing), integrating IoT components (Raspberry Pi, camera). The solution is projected to save $30k annually and increase operational efficiency by 50%(4 hours/shift walk-away time).• Ensured knowledge transfer and continuous operation by developing SOPs and training production personnel, enabling a seamless hand-off and sustaining productivity gains on the new line.

Education

• Sri Chaitanya Techno School, Bangalore

  High School Diploma, High school

  2013 — 2015

• Illinois Institute of Technology

  Master of Science - MS, Autonomous Systems and Robotics

• SRM IST Chennai

  Bachelor of Technology - BTech, Mechanical Engineering

• Illinois Institute of Technology

  Bachelor of Science - BS, Mechanical Engineering

• FIITJEE

  High School Diploma, MPC

  2016 — 2018