Ref. No. : CA - 14943 - (Designer & Product Developer – with 25.8 years in Plastic Industry)

Education

PGDBA (Operations) From Symbiosis Center For Distance Learning, in 2011 With A+ Grade

B. Tech (Mechanical) From College of Engineering, Trivandrum in 2000 With I class


Skill Sets

A Manager with 14 years experience in Machine design, costing, budgeting, planning building and machine layout Project Management, Design cycle Management, on the Job training

Work Experience

Manager Design
Since June 2004
Company Profile: manufacturer of Abrasives (Bonded, Coated, Non-Woven, Superabrasives and Thin Wheels) and Silicon Carbide. Manufactures and markets High Performance Refractories and Performance Plastics products.
Job Profile:
Senior professional with proven experience in Project Planning, Scope Management, Time Management, Cost Management, Risk Management, Quality Management.
Manage and guide a team of Engineers, internal and outsourced to ensure deliveries from concept design, design review, DFM, DFA, fabrication & Machining, assembly, testing and dispatch.
Do risk assessment and mitigation by HIRA (FMEA)
Estimating the cost of the project and budgeting.
Track and control the project cost in line with the budget.
Do Vendor evaluation, bid comparison, and order placing.
Record and monitor changes and ensure timely delivery as per project plan.
Initiate billing as per agreed milestones and follow monitor the cash flow.
Aid engineers in quickly acquiring skills and delivering.
Trained internal ISO internal auditor.

Assistant Manager- R&D 
Oct 2000 to Jun 2004
Company Profile: Manufacturer of Electronic Products & Components 
Job Profile:
Design & develop components for new models consisting of plastic and sheet-metal parts.
Design and development of jigs and fixtures for new models.

Significant Awards & Achievements
Achieved the ‘Profit beaters award’ for Year 2012 for contribution to project profitability by fast & accurate costing, tracking and control for the tyre building project.
Achieved the ‘New practiced award’ for Year 2011 for new concepts in Plant utility detailed design.
Planned and executed successfully the transferring of technical study and costing centre of glass furnace refractory from SEPR from France to India.

Key Projects
Manger-Project
Automatic weighing and batching system
Client: Saint Gobain abrasives, Australia
Team Size: 7
To automate a manual weighing and batching system for an existing plant in Melbourne. Raw materials have to be selected and weighed from a set of 26 storage container into a trolley as per product recipe and dumped into the mixer chute from where it will proceed to a mixer unit. This group company project resulted in manpower reduction, reduced cycle time and lesser wastage.
Key Responsibilities:
Project management, resource/ team management, planning & estimation, requirement analysis, functional & design specification, development & customization, testing, onsite implementation support
Review the design concepts, analyze for different working conditions and select the right concept, develop the design, do feasibility for manufacturing and assembly.
Plan, estimate, budget, track and reporting on project status, resource allocation & management
Coordinate with clients to ensure alignment of deliverables to business requirements

Tools used- MS Projects & Solid works
Design Manager
Dryer
Client: M/s BASF
Team Size: 8
The equipment is a gas fired drier of about 10m long, 3m height and 4m wide. It is used for automotive catalyst which needs to be dried in hot air. It consists of a burn chamber, drier chamber, height adjustable twin conveyor, dry air circulation blower etc. The criticalities included ensuring adequate insulation, reduced welded joints etc. The structural and insulation details, conveyor system, hot air ducting etc. were designed by PEG whereas the burner circuit was supplied by the client.
Key Responsibilities:
Project management, resource/ team management, planning & estimation, requirement analysis, functional & design specification, development & customization, testing
Review the design concept, integrating the different systems, feasibility for manufacturing and assembly.
Plan, estimate, budget, track and reporting on project status, resource allocation & management
Coordinate with clients for transfer of information, DAP, FAT, design improvement etc.

Tools used- MS Projects & Solid works
MTR –Master planning
Role: Project cordinator 
Client: M/s MTR Foods Pvt. Ltd
Team Size: 5
M/s MTR owns a food processing factory complex in two plots on either side of a public road with several buildings housed in it. Various food products are produced in these plants. These buildings and the associated utilities were developed over a period of time there by leaving lot of room for optimization. The project was to re-plan the whole complex to achieve efficient and effective systems viz. roads including traffic management interconnecting foot over bridge etc., ETP and STP drainage pipe lines, effective network of water tanks, locating new utilities storage systems like LPG, Diesel, Raw material storage and processing systems and also design of an integrated Firefighting system.
Key Responsibilities:
Understand the current operations of the plants in terms of material movement, raw material consumption point, type of vehicle and their movement etc.
Suggest new layout with sizing of utilities and their location, vehicle movement etc. after.
Plan and estimate, the cost of the project in coordination with Electrical and Civil departments.

Tools used- MS Projects & AutoCAD, MS Excel
Tyre Building machine 
Role: Manager-Project 
Client: M/s Michelin
Team Size: 17
This machine consisted of 15000 fabricated parts and numerous commercial items was the proprietary design of the customer. Managed the mechanical part cost estimation of the project. to preparing quote, by should costing and from vendors. After confirmed order the parts were fabricated at various vendor locations which included machined, welded, sheet metal, structural and cast parts. Ordering, tracking progress of parts, prioritizing parts critical to assembly and also for high priority assembly, Quality checking, assembling and dry test were also done in a timely manner.
Key Responsibilities:
Study the customer drawing, do should costing, and submit offer to customer.
Segregate into different types of parts as per manufacturing process obtain quote from two to three vendors, do bid comparison, negotiate and place order on L1.
Ensure quality of manufacturing, timely receipt of parts and assembly as per schedule.
Monitor and track the cost and time lines of the project with respect to the plan.

Tools used- MS Projects, & MS Excel
Utility design of New float glass plant  
Role: Project Manager 
Client: DTI, France 
Team Size: 16
The project aimed at detail design of the complete utilities and electrical layout of a new 800Tonnes / day float glass plant for Saint Gobain.  It had about 14 types of Utilities consisting of piping ducting & electrical layout running into about 900 man-hours. An overseas consultancy company was roped in to guide the team in basic utility design. Also a design service provider was hired with about 12 people to do the design and drafting work.
Key Responsibilities
Coordinate with all this agencies and to ensure a smooth transfer of information and data. 
Conduct design reviews and taking action and ensure the design outputs like technical specification, drawings & BOM are in accordance with PID and customer requirements.

Tools used - AutoCAD MEP, MS Projects
Double bowl mixer design and execution 
Role: Project Manager 
Client: M/s Grindwell Norton, Himachal
Team Size: 5
The project was to design a Double bowl mixer for in-house use. This machine was designed from concept. The concept design was developed and reviewed. Joint brain storming and design review with the electrical and automation team for functional and safety related sensing and interlocks. The part drawings were developed, which included material selection, component selection, machining, GD & T etc. to make fabrication drawings. The parts were manufactured at subcontractor facility, assembled, tested and shipped. The entire machine was designed and assembled with in-house facility.
Key Responsibilities:
Project management, resource/ team management, planning & estimation, requirement analysis, functional & design specification, development & customization, testing, onsite implementation support
Develop, review and freeze the design concept and then proceed with detail design
Do Design for manufacturing and design for assembly.
Plan,  estimate, budget, track and reporting on project status, resource allocation & management 
Coordinate with clients for transfer of information, DAP, FAT, design improvement etc.

Tools used- MS Projects, ProE wild fire 2
Setting up of offsite design center 
Role: Technical lead 
Client: SEPR, France
Team Size: 6
SEPR a group company of Saint Gobain, was into manufacturing glass furnace refractories. It has plants in 6 countries and had separate design and costing centers. The objective of the project was to develop a Central processing center in India to do the designing and costing for all these plants. This involved learning the design and pricing system and conventions from the existing center in France and training a team of Engineers back in India.
Key Responsibilities
Learning the design considerations of furnace refractories including material selection, machining, drilling, thermal expansion allowances, good design practices etc. from the office in France.
Transfer the learning to the team in India and train them on this process.
Guide the team in delivering while in learning stage.

Software used- ProE wild fire 2, SAP
Design of deflection yoke 
Role: Team member- Engineering 
Client: In-house requirement
Team Size: 4
The deflection yoke is an electronic component used to deflect the electron beams across the screen in the picture tube. It has a very unique shape which is arrived at by some calculation and by trial and error. After this the profile is scanned with a 3D scanner and the scanned curves are imported to ProE and the surface of the profile is generated. Then this surface is used to generate the tool used to mass produce this component.

Future Goals

Manage a team to deliver the organisational goals

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