Ref. No. : CA - 21349 - (Production - Moulding – with 30.4 years in Plastic Industry)

Education

Post Graduate Diploma in Business Management in 1996

Bachelor of Technology (Polymers (plastics)) in 1994

Skill Sets

More than 20 years of experience in Automobile Manufacturing industry. Extensive exposure to Lean manufacturing, JIT, TPM, KANBAN, 5S, SMED, ERP, SAP & Quality systems like QS, TS, ISO-14001, Customer specific requirements like ASES, MMA  etc.
   

Work Experience

DGM (Manufacturing Engineering & Projects)
Since Nov 2007
Company Profile: Provides Products And Services In The Automotive Industry. Products are Interior and exterior plastic products, Kinematic plastic parts, Automotive batteries, Radiators and inter coolers,
HVAC Systems, Exhaust and Emission After-Treatment Solutions, Rear-view mirrors, Suspension systems for commercial vehicles, Seating Systems for Commercial Vehicles, Large SMC parts, Sheet metal components.
Job Profile:
Facility planning, Finalization, Development & Installation, Pre production (Manufacturing / Quality/Cost/Delivery/Improvements/Projects)
Plan Molding, Painting & assembly facilities for all new programmes for all TACO (IPD) Domestic locations.
Finalize the technical specs for facilities.
Find out various probable suppliers for facilities.
Finalize the supplier after techno commercial evaluation.
Develop various facilities as per targets of productivity, cost, and timeline.
Evaluate the utilities, Manpower & space requirements for new projects.
Prepare the layout for new facilities.
Installation & commissioning of new facilities.
Productionisation of the new facilities.
Prove the new facilities as per planned productivity, manpower, quality targets.
Handover the facilities to regular production, maintenance team.
Periodic review of manufacturing process documents.
(PF,FMEA,CP)
Periodic re validation of processes.
Coordinate Engineering change management.
Take up & Implement In-house Improvement projects.
Evaluate & implement the suggestions received through suggestion scheme.
Develop new facilities (civil,infrastructure,machineries, assembly line set ups )
Develop logistics for all new projects

Sr. Manager  (Operations)
Apr 2005 to Nov 2007
Company Profile: Automotive Component Manufacturer And Supplier Of Exterior Lighting Systems, Powertrains, Electricals-electronics, Body And Chassis Parts To Leading Passenger Car And Motorcycle Segments Worldwide.
Job Profile: 
Ensure the smooth functioning of the Injection Molding, Painting shop (Production/PPC/ Maintenance/Tool room/Quality Assurance/New product development/stores/purchase/Projects)
Improve the OEE for the plant.
Reduce the RM Cost.
Reduce power cost.
Reduce labour cost.
Reduce freight cost.
Increase the net profit .
Achieve other set targets like customer ppm, delivery adherence.
Ensures implementation of TPM, ASES (Renault –Nissan Alliance Supplier Evaluation Standard), General Motors GM requirements.
Use SAP for planning, information analysis & data sharing.
Plan & commission the facilities for new projects.

Manager
Apr 2003 to Apr 2005
Company Name: Samsonite South Asia Pvt. Ltd
Job Profile:
Reporting to Asst Dir. Operations
Ensure the smooth functioning of the Injection Moulding, Vacuum forming, extrusion Depts.
Improve the efficiency of labour in the above Dept.
Reduce the scrap % arising from all the lines.
Identify cost saving areas and procedural improvements and propose the same to the management.
Achieve set targets.
Implementation of new projects.
Ensures 5S, SMED, Kanban, TPM, CI is being followed on the shop floor.
Provide guidelines to tackle recurring problems.
Long term planning of the activities & functioning of the related dept.
Provide technical support to develop the vendors for the related depts.
Use ERP for material reconciliation, data generation & analysis.
Establish production of new items or products like shells, components etc. as per Samsonite Quality standard..
To formulate & implement the adequate systems in the shop floor &.
Implementation of ISO 9001, ISO 14001.
Control the inventory of the materials in the above Depts. 
Improve the material yield in the above Depts.

Deputy Manager - Mould shop (Manufacturing)
Nov 1998 to Apr 2003
Company Name: Tata Auto Plastic Systems Ltd.
Job Profile:
Reporting to G.M.Operations
Setting & troubleshooting of the injection moulding process & assemblies, also train the operatives ,Zap leaders regarding the same.
Optimize the processes for quality & quantity
(Output).
Planning & control of manpower .
Plan the moulding production & assembly production according to Kanban.
Decide Mould sequencing based on stocks,Kanban & Dispatch plan given by CSG's.
Ensures moulding & Post moulding operations.
Educate sub ordinates about the quality requirement of  the product & works towards achieving zero defects.
Identify quality issues, trace the problem & solves it.
Ensures 5S, SMED, Kanban, TPM,CI is being followed on the shop floor
Set the targets for subordinates, cascading through the company's & Department's targets .
Review the performance of the subordinates through performance appraisals.
Assess the skill levels of the subordinates & identify the training needs
Develop the team members, subordinates for job flexibility.
Use ERP for material reconciliation, data generation & analysis.
Handling Online asslys including U.S.Welding, Vibration welding etc.
Member of  APQP, Change mgmt. team, Handling  PFMEA, Control plan.
Process flow Documentation & control for QS, TS, ISO 14000.
Evaluate the shop OEE & do the capacity planning as per projected business
Volumes & decide the subcontracting.
Developing the subcontractors (Vendors) by giving technical support.

Senior Engineer - Mould shop (Manufacturing)
1994 to Nov 1998
Company Name: Videocon Appliances Ltd.
Job Profile:
Setting & troubleshooting of the injection moulding process 
Planning & control of manpower .
Production planning & control.
Material handling.
Rejection control.
Delivery & cost control.
Set & follow Quality systems.

Achievements
Passed with D.T. (Distinction class) (77.34%) with overall Ist class at B.Tech (Polymers). 
Development & commissioning of assembly facilities for Tata Xenon project at Thailand.
Development of various TACO IPD facilities at Bangalore, Maan, Nasik, Talegaon, Chakan, Ranjangaon & Akurdi including Civil & Infrastructure development.
Installation of Paintshop facility at TACO IPD Maan Paintshop.
Developed & Installed state of the art technology facilities such as Thermocasing,In mould Graining, Laser scoring, Robotic cutting, welding, Cockpit assembly lines at TACO IPD plants.
Development & commissioning of assembly facilities at TACO IPD for Tata motors (Zest/Bolt, X2 Crossover, X1 Sedan, Microbus, World truck, Safari 18), Volkswagen (VW 250 & 251), GMI (M200, M300), Fiat (Linea & Punto), M&M (Xylo) projects. (Includes assy. facilities for Cockpit, Instrument panel, Door trims, Floor consoles, Bumpers etc.)
Successful completion of 2KT projects to reduce the rejection of Dashboard skin component at Tata Auto Plastic Systems Ltd from 8% to 1%.
Successful reduction in material cost by establish- ing a system of online material reconciliation & Component wt. Control at Tata Auto Plastic Systems ltd.
Established online assemblies of Door trims & bumpers, eliminating Inventory & reducing manpower at Current Company
Successfully completed Six Sigma Project for reduction in power cost at Tata Auto Plastic Systems ltd achieving reduction in power cost from 3.6 units/kg to 1.9 units/kg.
Execution of green field project for new plastic molding shop exclusive for four wheeler at Previous Company
Design & execution of total dust free set up for clear (transparent) molding for speedometer parts at Previous Company
Successful productionisation of new PC sheet extrusion line & vaccum formed luggage at Samsonite.
Improvement in the yield of the vaccum forming process at Samsonite by using six sigma methodology.
Successful commissioning & productionisation of seven new ChenHsong make Injection moulding machines at Videocon appliances ltd.
Successful development, trials & productionisation of new A/C, Dishwasher, & Washing m/c part molds at Videocon appliances ltd.

Major Projects Being Handled Presently :-
Plant expansion & Molding m/c installation at IPD Sanand plant for TML kite requirement – Production handover stage
Development & installation of Paint shop for bigger plastic parts specially bumpers at IPD at Jamshedpur plant – In installation stage.
Development & installation of state of the art robotic paint shop for bumpers for upcoming chakan facility – Supplier evaluation & finalization stage.

Systems Exposure :
Certified assessor for TBEM (Tata business excellence model) from Tata Quality management service (TQMS) Based on Malcolm Baldridge award.
Certified TS Internal auditor
Experience of Q S, TS, ISO –9001, ISO –14001 audits, Subordinates development on the above systems.
Implementation of 5S, TPM  activities by seeding of Model m/c, My m/c concept.
Solved chronic problems through six sigma methodology by using tools like 8D, DOE, 5W-2H etc.
Design & execution of ZAP, Kanban system for TACO IPD .
Implementation of CI & SMED activities through GEMBA Kaizen.
Implementation of Renault specific ASES (Alliance Supplier Evaluation Standard) as part of Mahindra –Renault pvt.ltd four wheeler supplier requirement.
Implementation of M & M MMA (Mass manufacturing audit) Requirement.

Future Goals

Accepting challenges & accomplishing them targeting Organizational and Personal Growth

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