Kunal Gaikwad

About Kunal Gaikwad

Industrial Engineer with over 4 years of experience improving operations in high-volume manufacturing and process-driven environments. Proficient in motion analysis, ergonomic assessments, and process optimization to reduce downtime, increase output, and enhan ce workplace safety. Delivered measurable improvements, including 18% equipment uptime increase and 25% layout efficiency gain. Proven ability to streamline workflows, reduce cycle times, and enhance labor forecasting. Proficient in data-driven manufacturing optimization using Excel automation, Minitab, QI Macros, and AutoCAD to support production and operational decision-making.

Experience

1. Industrial Engineer

   General Motors

   Jan 2025 — Present · IN, US

   Performed motion analysis across robotic weld stations, increasing equipment uptime by 18% through Excel-QI macro simulations, identifying bottlenecks via timestamp validation, and eliminating minor operational inefficiencies.• Reconstructed assembly layout utilizing AutoCAD layering features, decreasing inter-cell travel distance by 25%, allowing better forklift navigation, and reclaiming 160 sq. ft. workspace for inventory staging zones.• Authored customized work instructions integrating ergonomic control principles, minimizing repetitive strain injuries by 22% through adjusted reach envelopes, height placements, and anti-fatigue floor mat deployment.• Modeled headcount utilization forecasts in Microsoft Excel to support short-term capacity planning and daily production scheduling, improving shift-level production targets by 14% while supporting supervisor dashboards with real-time labor status.• Facilitated root cause assessments during daily standups, resolving twelve recurring abnormalities by correlating hourly data trends, enforcing immediate countermeasures, and updating corrective actions using Gantt-based issue trackers.• Coordinated with production, quality, maintenance, and safety teams to prioritize improvement actions and align countermeasures with daily operational targets.

Education

• Purdue University Northwest

  Master's degree, Industrial Engineering

• Savitribai Phule Pune University

  Bachelor of Engineering - BE, Mechanical Engineering