• Gender: Male
• Age: 57
• Designation: Manager
• Highest Education Level: Post Graduate Diploma
• Current Gross Salary: INR  700000 /Annum
• Expected Gross Salary: INR  900000 /Annum
• Preferred Country: India
• Preferred Location: North Region
• Work Experience: 29.7 Year(s)

Education

Post Graduate Diploma in Plastic Engineering (PGD-PE) from Central Institute of Plastic Engineering &Technology (CIPET), Lucknow in 1995.
BE (Mechanical) from Gauhati University in 1992

Skill Sets

Key Skills: Production, PPC Operations, Maintenance, Vendor Development, Industrial Engineering and Customer Coordination.
IT Skills: MS Office, Internet Browsing and ERP Implementation.

Work Experience

Manager- Marketing & Service (North East Region)
Since Feb 2010
Company Profile: Manufacturers of Plastics Auxiliary machines.

Manager - Production
Aug 2006 - Jan 2010
Company Profile: One of the leading company in the field of Commodity Plastic Processing having well established injection molding shop, Blow Moulding and Extrusion machines. Manufacturers of Mineral Water Bottle, Extrusion Sheet, PET Preform etc.

Manager - Manufacturing
April 1996 - July 2006
Videocon Industries Ltd (Formerly M/S Electrolux Ltd)
Company Profile: Manufacturing home appliance product like Refrigerator, Washing Machine, Colour TV, LCD etc.

Development Engineer
July 1995 - Mar 1996
Ranee Polymers Pvt Ltd.
Company Profile: Pioneers in the field of Injection and Blow Molding of engineering plastic processing and OEMS of MUL, Hero Groups, Escorts Yamaha, Daewoo Motors, and BPL etc.

Job Profile:
Production:
Monitoring the Production processes & identifying deviations towards ensuring that the same will consistently manufacture products meeting pre-determined specifications and quality attributes.
Ensuring maintenance of proper Working Conditions, Housekeeping, Discipline and Safety at the workstation by following 5-S, KANBAN principles.
Preparing & implementing Operating Procedures and Work Instructions.
Planning & implementing the preventive & predictive maintenance schedules for improving the overall reliability and safety of plant, personnel and production processes.
Interacting with the Quality Department for detection of potential deficiencies and implementing corrective actions - Maintaining Quality Systems and Process Control Records.
Machine setting and control over machine setting parameter of injection and blow molding machine, vacuum forming and P.U. Foaming and trouble shooting of quality problem and conducting new mould trials.
Use of KAIZEN and Quality Circle activities for continual improvement in Productivity, Quality & Safety of product.

Production Planning and Control:
Complete Analysis of machine capacity Utilization and Machine feasibility study wrt Machine combination and preparation of date wise planning table for production
Paint Booth and Assembly Line Planning wrt Capacity Utilization.
Cost Effective Material planning (as per BOM) and computing for minimum inventory levels in Moulding, Forming and Foaming Dept. as per quarterly and monthly forecast/schedule given by Marketing through MRP running in ERP System.
Preparing mould loading schedule as per customer requirement taking into consideration efficient machine utilization.
Man Power planning wrt Mold Machine combination and as per product in Assembly Line.
To ensure timely production and quality control based on marketing schedule and Customer requirement.
Dispatch planning and monitoring timely dispatch based on Marketing schedule and Customer requirement.
WIP control in shop floor by monitoring the Material Issue and Consumption report through ERP.
Providing the production schedule to Job work Vendor and get the material on time to meet the customer schedule.
Played a key role in successful implementation of ERP Packages -SAP in the organisation.

Maintenance Operations
Monitoring the maintenance of auxiliary equipment like Mould, Fixtures, SPM, MTC and Water Chiller on time.
Preventing occurrence of failures, solving failures in presence and dealing with highly stressful situations.
Assisting the maintenance team to complete the preventive maintenance of Injection Molding Machine, Vacuum forming machine, Foaming machine as per schedule.
Ensuring all the maintenance activity has been done as per TPM guideline.

Vendor Development:
Identifying and developing a dedicated and alternate vendor source for, achieving cost effective purchases of raw materials and reduction in delivery time.
Assessing the performance of the vendors based on various criterions such as percentage for, rejections, quality improvement rate, timely delivery, and credit terms.
Following up with vendors for timely deliveries, quality checks as well as timely payments.
Coordinating with accounts department regarding payment for domestic and overseas vendors.
Vendor audit to asses and evaluate the rating of vendor for new business.
Regular interaction with overseas vendors for material, price negotiation and delivery.
Development of part /components as per PPAP/APQP guidelines.
Handling design changes/modification, co-ordination between engineering & supplier

Industrial Engineering:
Examining all activities related with the product manufacturing through Value Stream Mapping, Drawing Current state & Future map.
Calculation of OEE, Non defective rate & Availability of all machines for monitoring the performance of all manufacturing related departments.
Expertise in conducting Cycle Time study & setting Production norms for all operations in injection molding shop & Assembly Shop.
Proficient in using Work measurement techniques like Line balancing and Motion study for achieving maximum production with minimum effort.
Designing new layouts and improving existing layouts of machines for maximum utilization of resources
Calculation of M/C hour rates and estimation of Pay back for newly proposed machines
Activity based costing of in house product manufactured as well as job work product.

Lean Manufacturing:
Increasing Productivity by eliminating wastes using principles of TPS (Toyota Production System).
Effective analysis of Man & Machine Loss hours and PPM data for identifying the bottlenecks for improving productivity and calculating cost of poor quality.
Conversant with Cost Savings in the company by controlling various factors i.e. Tools, Consumables, Water, Electricity etc.
Conducting trials of new Tools & Consumables for improvement by process re engineering, technology absorption and new products.
Conceptualizing and implementing low cost automation for cost savings by reducing manpower and optimum utilization of machines.
Use of 7 QC Tools like SPC, Pareto Analysis etc. for analyzing data of improvement projects under TQM activities.
Scrap Management of both avoidable and unavoidable.

Improvement Training Attended:
Internal Training Program on ISO-9001, 5S, KANBAN, Six Sigma and Quality Circle.
One week Training in Lean Manufacturing Technique.
One Month Training on Maynord Operation Sequence Technique (MOST)

Achievement:
Initiated the quality circle, thereby achieving significant reduction in rejection rate.
Played a key role in reducing the Cycle Time by fast and smooth flow of material in different manufacturing phases.
Significantly maintained on time delivery index of over 100% on a weekly basis.
Successfully established the Machine scheduling process in absence of a system based automated solution.
Established the monthly Inventory reconciliation process in running operations environment at an accuracy level of 99%.
Instrumental in reducing the inventory level in WIP on shop floor.
Successfully incorporated KANBAN system in different Manufacturing Shop.

Knowledge Purview:
Moulding Machine:
Injection Moulding Windsor, JSW, L&T, Ferramatic Capacity (30T to 1600T)
Blow Moulding Capacity up to 30 Ltr (Rana & Sons, FKI, EKOU PET)
Thermoforming Capacity up to 500 Ltr (RIGO, CHEMEI, KS-200, ATL)
PU Foaming (CANON, Perros Drum, Lehel Drum, Mariested etc.)

Material Processed:
HIPS, PS, ABS, PBT, GPPS, PET, PP, PPO, POM, Polycarbonate, Nylon 66.

Future Goals

To serve the organization with sincerity and honesty by making best use of my skills and capabilities and upholding the dignity of being a true engineer.