Ref. No. : CA - 16767 - (Quality – with 18.2 years in Plastic Industry)

Education

Masters in Mechanical Engineering From Georgia Institute of Technology in Dec 2008 

Bachelor of Science in Mechanical Engineering From University of Pune in June 2006

Skill Sets

Experienced in Statistical & Optimization Computing Software, Design & Modeling software, ERP software
Matlab/simulink, SAP, MS Project, Visio, CAPS, SAS, MOST(Accenture Certified), MS Access

Work Experience

Quality Assurance - Plant Head 
Since May 2012
Company Profile: Leading manufacturer of tyres
Job Profile:
Risk assessment & Value Stream Mapping; Responsible for using Gap Analysis for creating & implementing contingency plans at intervals of 2yrs, 1yr and 6 months before project commencement. All Critical risks identified were treated before project startup
Project Management; Identified Critical Path, created Gantt Charts and implemented modular deployment. All machines imported from France & China were Installed and Commissioned 2 weeks before Project milestone
Systems Deployment; Quality Management Systems and support software developed from base up and deployed for ERP, Data management, Performance Tracking, Analysis tools, Product Traceability and Production Planning
Audit Preparation; Performed diagnostics to identify gaps and Supervised progress of Global Action Plan to get
Certification for ISI, ISO 16949, ISO 14000 and Michelin Quality System (MQS)
Career Development; Mentored local hires focusing on competency development to accelerate career growth
Event Management-First Tyre Launch; Organized the launch of Michelin's First Tyre made in India for 1200+ attendees
which also signaled the start of Michelin's production in India to the Michelin Network and the Global Media
Achievements
Even with 6 months construction delays, First tyre rolled out in July'13 and reached 82% production capacity by Jan'14
BIS Audit successfully completed and ISI certification awarded in Dec'13
Michelin Leadership award for accelerating industrial performance; COQ reduced from 21% to 3.5% & Production
capacity ramped up from 250 tyres/day to 850 tyres/day while complying to Safety & Quality requirements.

Responsibilities after Startup:
Evaluate Systems and Improve Maturity; Optimized Plant performance by restructuring the Organization, used MMW
Approach (similar to CMMI) for Improving effectiveness of systems and Standardizing Best practices
Contract Agreements & Client Relations; Created Supplier Contracts based on Customer requirements and focused on
implementing better communication channels and developing Visual performance scorecards to promote faster response 
Strategy Development; Defined Annual and Five year Quality Orientation for the Plant and identified the progress areas with clear guidelines and objectives. Used Manning tools and Career Charts for resource allocation and established short, medium and long term Performance improvement teams for sustainable progress of Quality (COQ,VOC,etc.)
Accelerate Industrialization; Reduced Concept to Practice by 20% for new products/processes through parallel development followed by a robust deployment in production phase Innovation & Benchmarking; Lead monthly meetings with other Michelin plants in Asia Zone (Thailand, China & Japan) focused on improving performance by sharing innovate ideas and use of Michelin Quality Tools (BIB Tools) Crisis Management; Lead and Resolved 4 critical issues using Problem Solving basics as platform and innovative thought process for Design of Experiments. Team's structure was defined to promote rapid analysis of test and drafting multiple configurations for Final Solution. The Solutions implemented were recognized and adopted in other plants 
Achievements
BIB Excellence award for leading Continuous Improvement workshops which reduced COQ by 54% (3.5% in Feb'15 to
1.6% in Sep'15) and a further 15% reduction identified, estimated savings in excess of 40 Lakhs INR for 2015
BIB Excellence award for fastest deployment of Michelin Quality Systems (MDP-Q) in Michelin Asia (<10 months)

Quality Assurance Manager
Oct 2011 To April 2012
Company Profile: A Manufacturing Plant, Skill Training & Career Counselling Program.
Job Profile:
Productivity Gain; Managed the activity of the technical project teams to achieve the Quality objectives of Production
Operations and reduce Cycle time/Tyre from 5.8 min/tyre to 3.19 min/tyre
Quality Planning; Improved “First time right” by 8% using Gap analysis, Ergonomic Studies and FMEA
Data Analytics; Analyzed data & trends using statistical tools and developed improvement plans to enhance the process
performance; Gained 0.2 CpK,Masked 85% of Non-value added activities,Reduced Ergonomic impact by 20%
New Process Deployment; Created detailed procedure documenting the steps and milestones for Homologation &
Qualification of new processes, reducing the lead time by 3 weeks
Training & Mentoring; Collaborated with HR (Michelin US & India) to create a tailor-made training program for engineers
and operators hired in India (>300 employees) and a Cultural orientation plan for US employees
Achievements:
Received Employee recognition award for piloting a Crisis Management Team which was able to contain the risk, minimize stoppage and restart production with a clear ramp up and sustainability plan; eliminated losses of ~$240000

Quality Engineer
Feb 2010 To Sep 2011
Company Name: Michelin Tires Pvt. Ltd
Company Profile: A Tyre Manufacturing Plant, Skill Training & Career Counselling Program.
Job Profile:
Waste reduction Project; Facilitated process control and implemented MTP (Lockdown) on 3 processes achieving a cost
saving of $15,000/yr due to reduction in material wastage
New Process Development; Conducted Opportunity & Feasibility Studies for a 2nd Stage Tyre Processing Machine and
drafted the instruction manual which was later used for deploying 6 machines in Michelin Canada
Document Management; Created work methods, instructions, process referentials and L1/L2 verification plans
Continuous Improvement; Applied Problem Solving tools (Cause/Effect,etc.) achieve Annual COQ reduction by 15%

Continuous Improvement Engineer
May 2009 To Jan 2010
Company Name: Michelin Tires Pvt. Ltd
Company Profile: CPV-Mold Manufacturing
Job Profile:
Cycle time improvement and manning optimization using micro planning tools (MOST, Simogram, Gantt, etc.)
Reduced Manufacturing Costs by 6% using Value Stream Mapping, Process evolution & Optimizing Uptime
Achievements:
Awarded “Best Michelin CPV Employee-2009” for Improving Overall Productivity on a bottleneck Engraving Machine
by 15%, potential revenue growth of $90000/yr

Controls Lab Research Assistant
July 2007 To April 2009
Company Name: Georgia Institute of Technology
Job Profile:
Research; Defined experiments, conducted simulation, analyzed results and implemented corrective algorithms

Production Planner & Controller
July 2006 To June 2007
Company Name: Daimler India Ltd
Job Profile:
Production Planning; Created Production Plans based on Pull Mechanism & Lead Inventory control activities
KPI/KRA Development; Responsible for developing Delivery scorecard and driving actions to achieve commitments
Presented performance charts to Senior Management in daily/monthly meetings


Areas Of Expertise:
Scaling Operations
Continuous Improvement
Project Management
ISO 16949
CAPA
Business Process Mapping
PLM
Strategy Development 
Supplier and Contract Management
Change Management
Audit & Risk Management
Six Sigma #Lean

Functional Skills:
Quality Assurance & Control
Total Quality Management
R&D
Installation & Commissioning
Industrial Engineering
Production Planning
Supply Chain & Logistics
KPI/KRA Development



Future Goals

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