Ref. No. : CA - 18225 - (Designer & Product Developer – with 18.7 years in Plastic Industry)

Education

Post-graduation - Tool, Die & Mold Design From Central Institute of Tool Design, Hyderabad in 2008

B. Tech. (Mechanical Engineering) From Dr. B A Technological University in 2005

Skill Sets

Design & Development:
Packaging Design And Development | Bulk Container Injection Moulding | FMCG IM/BM Packaging
A versatile professional with proven leadership skills and technical expertise in designing and developing products right from ideation & concept which would involve evaluation & testing to implementation till product launch. Managing projects, making and maintaining robust project plan for optimum and effective utilization of resources, first time right approach at development phase for better product deliverables and contributing to line implementation with focus on achieving excellence in product development

Work Experience

Head – D & D Department - Dec 2015
Deputy Manager - Apr 2012 - Jan 2015
Sr. Engineer - Apr 2009 - Mar 2012
Engineer - Feb 2008 - Mar 2009
Company Profile:Leading manufacturer of household appliances
Job Profile:
Heading Designing and Development team for bulk container injection mould. ( Team Size - 5 engineers )
Heading Designing sand Development team for FMCG Packaging ( IM, BM, IBM, EBM, ISBM) (Team Size – 7 Engineers)
Heading R&D Center for Development of Injection mould for bulk containers. ( Team Size – 13 Engineers)

Bulk Packaging :
Developing new Bulk packaging for various clients like APL, Burger, ETC
Injection mould design within department.
Mapping tool room loading and capacity and offloading tool manufacturing to outside mould makers.
Identifying mould requirements for all 14 plants and making new moulds accordingly.
Addressing all mould maintenance and breakdown issues for all 14 manufacturing locations.
Budgeting, Resource mapping, Capacity Mapping, Gap Analysis and recruitment.

FMCG Packaging:
After Marketing gets requirement from any of the FMCG clients, deport technical person for direct interaction with client.
Understand clients requirements and acceptations, communicated new advancement, technical feasibility and formulated acceptance criteria to validate final product.
Make design proposals and first time prototypes to be presented to client for selection of final design.
Develop final 3D and 2D for proposed product; get alignment from Mould maker, manufacturing facility on design tolerances and tooling and process capabilities.
Release find product drawing for Mould quotation and mould making.
T0 and T1 trials in presence of client and manufacturing representative to understand process parameters and cycle time optimization.
Project handover to Manufacturing plant for production.
Address post production issue and concerns related to maintenance and breakdown.

Innovation:
Look for any new technology and advancement in the field of Moulding.
Interact with clients to understand their need and pain areas with current products.
Proposed innovation solution and work on development of new innovation designs and ideas.
Applied for Patent on “Breathable Membrane Plug Design” in March’2016.

Deputation:
BM Refrigeration - Europe as I &W Sub-System Lead - NPD
DC Refrigeration, India during Apr’13 - Apr’14 as Structures & Feature Lead
Built-in Refrigeration, USA during Apr’12 - Mar’13 as Features Lead – NPD
XL Refrigeration, Mexico as Features Lead ( NPD) from Apr'10 to Dec'11

Key Result Areas:
I &W Sub-System Lead (NPD) – Europe BM Refrigeration
Designing and developing in-door water dispenser system with speed well before schedule
Coordinating with Marketing and GCD to understand product level requirement and deliverables with basic rendering from GCD
Breaking-down subsystem into parts and deriving system level schedule from product level schedule
Describing interfaces and interacting with other subsystem to ensure final design is meeting all product level requirements
Scheming exterior dispenser parts like dispenser housing, paddle, UI housing, LED lighting, drip tray, water valve actuation and spout, foamed-in components like canal & tank mounting and door lugs
Managing interior features like water tank, house-in-door bin, water filter assembly & lead
Directing with tool makers to understand possible tool construction and address any changes required to meet tooling consideration without losing functionality
Defining assembly process and condensing with manufacturing to establish line setup and process plan
Developing prototypes to test fit & function, functionality and address any foreseen issues for pilot 1 samples, soft tool and test soft tooled parts to address PALO testing requirements
Working towards tool development, samples, approval testing, PPAP, inventory building and production

Lead Structures & Feature – DC Refrigeration, India
Benchmarking current DC refrigerator for structures and features, face-lift product to enable the DC Refrigerator beat competition with best innovative features
Generating costed BOM to estimate Product BOM cost and tooling estimate for all structural parts
Owning all shelves, door bins and drawer with better aesthetics and accessibility
Managing class crisper drawer with 85 % Extension and first DC refrigerator in Indian market with separate crisper drawer
Designing cabinet liner and door for convertible product (single & double door) and replaceable mullion to convert single door cabinet into double door & post foaming operation
Defining product level DFMEA for all structural parts, DVPNR to identify all approval testing to be done
Collaborating with GCD, marketing, manufacturing and other stakeholders for product definition and delivery

Features Lead (NPD)-Built-in Refrigeration USA
Defining product layout for IDI dispenser on built-in SXS and FDBM refrigerator and designing dispenser housing assembly including ice dispensing and crushing mechanism
Working on layout for IDI Dispenser for Built-in FDBM refrigerator; working out costed BOM estimate from converting NIDI product into IDI, layout for false mullion & ice compartment and designing air routing for In-door Icemaker on FDBM product
Providing required in-puts for different sub-systems like structures, features, cooling to simultaneously come up with final design
Managing master assembly and keeping track to all changes during product development
Building prototypes for all new parts for first fit-function evaluation, products for evaluation testing and fit-function evaluation and maintaining product level FMEA and DVPNR
XL Mega Project
Worked on New development project for XL Refrigeration (New Platform –Mega Project- NAR-Mexico-Refrigeration)
Worked for design and development of internal features (Mechanical Structure) XL Refrigeration
Developed 63 features, with help of 4 CAD Engineers
Carried featured development starting from GCD inputs, marketing requirements, technology review, concept development, engineering evaluation, technical design reviews, prototype building, tooling review and verification, pilot run till, process variation study, measure and corrective action till implementation
Ensured Feature modularity between TM Refrigerators and BM Refrigerators

Trainee Engineer-Production
Mar 2005 To Jan 2006
Company Name: Blue Star Ltd
Job Profile:
Achieved daily production target for AHU build; monitored production requirement for each shift & day; understood drawing to be used in AHU build; coordinated with workers to explain work requirement, type of blower, panel & extrusions usage

TRAININGS ADDED
2012 Operational Excellence Black Belt from Whirlpool USA
2010 Operational Excellence Green Belt from Whirlpool of India
2009 Consumer Safety Training from Whirlpool of India
2011 DFV

Highlights:
Rewarded “Employee of the Quarter” Award for 3Q’2010 for work done on XL Project
Implemented cost projects for Mexico SXS Refrigerator platform worth USD 800,000 cash flow per year and quality projects worth 6000 ppm per year
Conducted tear down and DFV workshop and identified opportunity for cost elimination
Contributed to SIR reduction by reading through call service call and understanding potential areas
Drove cost opportunities right from ideation to implementation which included concept generation, business case ROI, FMEA, Proto-making, testing, PALO, tool modification, new build, inventory control, supplier interaction and so on
Interacted with consumers and service guys to understand actual failure; defined product map, thought map, process map to define factors for each function and error stare
Studied field return parts and physics of failure; identified and defined Y=f(x)+n and various x’s; analyzed COV & DOE to understand impact or individual factures and interactions
Identified opportunities for cost reduction & implemented projects which generated an annual saving of USD 500,000 cash flow
Targeted high SIR areas and implemented project which reduced 6000 PPM SIR per year
Completed quality projects within the time by taking by taking 100 initiatives
Steered the implementation of quality initiatives such as Learn before Do, Back to Basics, Though Mapping, Virtual Intelligence that instilled basic quality philosophies of doing things right the first time, resulting in an 8% reduction in company rework cost
Pivotal in streamlining processes through measures such as Project Scheduling, DFMEA, DVPnR, Lean, First Time Right
Successfully executed cost optimization projects such as Air Duct redesign to eliminate Air Scoop, achieved same cooling with less part count, less part cost, less assembly cost and increased productivity


PROFILE SNAPSHOT
A result-oriented professional offering 10+ years of a successful career with diverse roles distinguished by commended performance in:
Proven leadership skills to lead multiple teams (within department) towards excellence and innovative approve of Design and Development.
Coordination and communication within cross-functional team within organization and with multiple clients.
Spearheading the entire functions related to new product development, Plastic Injection Moulding, Blow moulding, IBM, EBM, ISBM, cost & quality improvement, value engineering, designing, material selection and manufacturing and working at geographical locations across North America & Mexico
Leading new product development right from ideation to implementation
Reducing cost through technical evaluation and design optimization, benchmarking, tear-down & DFV workshop
New product development and bagged the ‘Quality & Innovator Award’ for patent filed in Europe with respect to design
Filed 1 US patent refrigerator dispenser and method of illuminating the dispenser including 3 other patents and IDS under investigation
Deploying methodologies to analyze various production processes; effective in managing activities for minimizing escalations, reducing rejection, saving energy & realizing efficiencies
Managing projects and suggesting innovative ideas, resolving issues through brainstorming in manufacturing and designs
Analyzing design modification and improvement areas, suggesting process change on the product and line implementation
Conducting Tolerance Stack up Analysis (1D & 2D) to understand and capture process capability and process variation incorporating suitable tolerance on individual components to make sure 100% assembly
Track record of excellence in route causes analysis using tools like MSE, COV & DOE
Six Sigma professional with hands on expertise and knowledge of A3, 8D, DVPnR, FMEA, Process Map, Product Map, Thought Map,
Excellence in driving cost saving opportunities through concept generation & business case
Key role in setting up process for various functions in design department with SOP for every single activity and project getting driven.

Future Goals

growth

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