Babak Beglarzadeh · Manufacturing transformation leader

Engineering systems.
Elevating operations.

I help manufacturers improve operational performance, solve complex production challenges, and make better technology and process decisions. My approach combines manufacturing engineering, operational excellence, industrial analytics, and precision metrology to turn technical insight into practical, measurable improvements.

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14+Years in engineering and operations
100+CNC machines in connectivity scope
35%Reduction in rework and variation
67.95%Reported precision-correlation improvement
Consulting Services

Practical solutions for complex manufacturing challenges.

I work with manufacturers to identify operational constraints, improve process performance, and evaluate technical solutions. Each engagement is scoped around the client's objectives, available data, operating environment, and measurable business priorities.

01

Operational Excellence & Manufacturing Performance

Improve productivity, throughput, delivery performance, and operational control through structured problem solving and measurable improvement initiatives.

Services include

  • Manufacturing performance and bottleneck assessments
  • KPI frameworks, OEE, downtime, and cycle-time analysis
  • Lean manufacturing and continuous improvement
  • Improvement roadmaps and implementation governance

Typical deliverables: Baseline assessment, prioritized improvement plan, business case, and performance-tracking framework.

Supporting expertise: Work Center OPEX, TPM, 5S, cross-functional technical leadership, and scalable standard work.

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02

Smart Manufacturing & Industrial Analytics

Turn manufacturing data into actionable insight to support better decisions about machine utilization, production performance, and operational reliability.

Services include

  • CNC connectivity and machine-monitoring strategy
  • Power BI dashboards and manufacturing analytics
  • Utilization, spindle uptime, downtime, and cycle-time analysis
  • Industry 4.0 feasibility studies and predictive-analytics roadmaps

Typical deliverables: Data and KPI requirements, dashboard or pilot scope, technology assessment, and implementation roadmap.

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03

Manufacturing Quality & Process Capability

Investigate process variation, measurement discrepancies, and inspection constraints using engineering analysis and evidence-based problem solving.

Services include

  • Statistical process control and variation analysis
  • Measurement correlation and process capability studies
  • CMM utilization and inspection workflow improvement
  • Precision manufacturing and measurement strategy

Typical deliverables: Technical assessment, root-cause findings, corrective-action recommendations, and a verification plan.

Supporting expertise: Machine-tool precision, dimensional metrology, GD&T, master-part correlation, and FOD prevention.

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04

Industrial Projects & Technology Implementation

Evaluate and develop practical manufacturing solutions that combine technical feasibility, process requirements, investment economics, and implementation planning.

Services include

  • Automation and semi-automation feasibility assessments
  • Equipment selection and technical requirements
  • CAPEX, ROI, and make-versus-buy analysis
  • Precision processing, workholding, and process development
  • Project coordination and acceptance criteria

Typical deliverables: Feasibility assessment, technical scope, business case, project roadmap, and measurable acceptance criteria.

Specialized expertise: AMS 2700 passivation, Level 100–200 precision processing, hydrostatic pressure testing up to 7,500 psi, controlled drying, polishing, deburring, and automation-ready workholding.

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Selected work

Projects built around measurable impact.

A selection of manufacturing transformation programs spanning connected operations, precision quality, automation, and post-machining excellence.

Flagship case studies

The challenge, the engineering approach, and the evidence.

Three anonymized examples explain how I approach manufacturing problems. Each identifies its implementation status, verification requirements, and lessons for other manufacturers.

CNC connectivity & manufacturing analytics

From Machine Signals to Production Visibility

A multi-controller roadmap that connects manufacturing questions, machine signals, KPI definitions, and planned Power BI reporting.

Roadmap & phased deployment · 100+ machines in scopeRead case study →
SPC & measurement correlation

Improving Confidence in Precision Manufacturing Measurements

Master-part correlation and structured measurement comparisons for tight-tolerance features, with the reported result and evidence limits clearly identified.

Implemented method · reported result requires verification recordsRead case study →
CMM throughput & inspection automation

Designing an Automation-Ready Inspection Workflow

A proposed operating model combining part-family fixtures, external preparation, batch handling, and controlled unattended inspection.

Program under development · 24/7 is a targetRead case study →

Explore the wider project portfolio.

Digital manufacturing

Industry 4.0 CNC Connectivity

Designed the roadmap for multi-controller data capture across Fanuc, Haas, Heidenhain, and Mitsubishi platforms. Converted machine signals into Power BI visibility for utilization, spindle uptime, cycle performance, tools, and alarms.

100+ machines in deployment scope
Closed-loop quality

Automated On-Machine Measurement

Advanced probing, drift monitoring, and tool-wear offset strategies to stabilize critical machining characteristics and reduce operator-dependent variation.

35% less rework and variation
Precision systems

SPC & Measurement Correlation

Introduced master-part correlation and a repeatable verification approach for extremely tight tolerances.

±4 µm critical features controlled
Inspection automation

24/7 CMM Throughput Program

Developed the path toward unattended inspection using modular multi-part fixtures, batching logic, and automation-ready workholding.

24/7 target operating model
Process industrialization

AMS 2700 Passivation

Built the business and operating case for an in-house citric passivation line, strengthening lead-time and process control.

78% external-cost reduction in year two
Process industrialization

Level 100–200 Precision Processing

Developed precision-processing methods for Level 100–200 cleanliness requirements, integrating controlled washing, directed DI-water rinsing, targeted drying, contamination prevention, and final inspection.

100–200 cleanliness levels
Process industrialization

Hydrostatic Pressure Testing

Developed a hydrostatic test process for pressures up to 7,500 psi using DI water, defined pressure-hold controls, and a no-visible-leak acceptance criterion to verify component integrity.

Up to 7,500 psi hydrostatic test pressure
Smart maintenance

AI & ML Manufacturing Modules

Defined applied analytics concepts for tool wear, spindle health, cycle-time variance, machine condition, and downtime-risk prediction.

5 predictive use cases
Post-machining excellence

Processing, Polishing & FOD Control

Integrated equipment upgrades, controlled finishing methods, traceability, 10× visual inspection, borescope verification, targeted drying, and geometry-specific cleanliness controls.

50% reduction in processing touch time
Precision rotating systems

Automatic Dynamic Balancing for Turbochargers & Components

Evaluating automated dynamic balancing machines for turbocharger compressor wheels, turbine rotors, and complete shaft assemblies. The program defines rotor-specific workholding, measurement capability, unbalance correction methods, and production integration, with acceptance based on residual-unbalance limits and repeatability.

The objective is a scalable balancing process that supports rotor quality, vibration control, and consistent production performance.

Equipment selection & process development
Space-component assembly

Precision Bearing Swaging & Proof-Load Testing

Developing a controlled roller-swaging and proof-load verification process for space-component bearing assemblies. The scope combines application-specific tooling, controlled bearing retention, and calibrated load and displacement measurement to assess installation integrity against engineering requirements.

Planning emphasizes test automation, traceable results, and repeatable acceptance criteria.

Assembly & test process development
Machine-tool precision & doctoral research

Precision starts with understanding the machine.

My PhD research at Polytechnique Montréal investigated how machine-tool geometry and structural compliance influence tool-to-workpiece accuracy under quasi-static loading. This work provides the research foundation for my approach to precision machining, dimensional metrology, and manufacturing process capability.

Structural compliance · 2021

Machine-Tool Joint Compliance

Co-developed a kinematic and compliance model to estimate equivalent joint compliance from loaded circular tests. Combined radial force and displacement measurements from a loaded double ball bar to characterize how joint behaviour affects tool-to-workpiece position under load.

CIRP Journal of Manufacturing Science and TechnologyRead publication ↗
Precision modelling · 2022

Elasto-Geometric Error Separation

Developed a modelling framework that estimates geometric errors and joint compliance together using tests at multiple force levels. Separates geometry-related deviations from elastic deflection, providing a quantitative basis for diagnosing machine accuracy under different loading conditions.

The International Journal of Advanced Manufacturing TechnologyRead publication ↗
Sensorless metrology · 2024

Sensorless Loaded Testing

Developed a ball-roller bearing test method that uses CNC encoder and motor-current signals to estimate applied force and displacement. Validated force estimates against dynamometer measurements and compliance estimates using a flexure rig, demonstrating compliance assessment through internal machine data.

Journal of Manufacturing ProcessesRead publication ↗

Selected research projects from my doctoral work and related peer-reviewed publications.

Leadership approach

Technical depth. Practical execution.

I treat improvement as an operating system, not a collection of isolated events. Every initiative must create clear ownership, reliable standards, visible performance, and a path to sustainment.

01 / Diagnose

See the system

Observe the work, validate data, define the constraint, and separate symptoms from root causes.

02 / Design

Engineer the solution

Combine process knowledge, quality controls, automation, and economics into a robust concept.

03 / Deploy

Make change usable

Pilot at the point of work, involve operators, control risk, and translate the concept into standard work.

04 / Sustain

Build the rhythm

Measure outcomes, assign accountability, develop capability, and continuously refine the system.

Leadership • Engineering • Transformation

Build better systems.
Deliver better operations.

Partnering with manufacturers to advance operational excellence, strengthen quality, and enhance process capability through specialized consulting and the delivery of complex industrial projects.

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