• Gender: Male
• Age: 51
• Designation: Manager
• Highest Education Level: Post Graduate Diploma
• Current Gross Salary: INR  1100000 /Annum
• Expected Gross Salary: INR  1200000 /Annum
• Preferred Country: India
• Notice Period: 7  Days
• Preferred Location: Anywhere
• Work Experience: 26.8 Year(s)

Education

Post Graduate Diploma in Plastics Processing Technology from CIPET, Chennai University and under Ministry Of Chemical and Fertilizer in 1998.
B.Sc in Chemistry from Deen Dayal Upadhyay, Gorakhpur University in 1993.

Skill Sets

Computer Knowledge:
Basic knowledge of computer.

Technical Expertise:
Injection Moulding M/c-60 to 2500 Ton
Strong Plastic Processing knowledge.
Make Mitsubishi, JSW (All electric and Hydraulic), Toshiba, MIKI, Windsor, Super & Jet Master, FANUC and L&T
Gas Assist Moulding of Battlefield & Gain (USA)
Use of Hot Runner Temp., Controller and Hydraulic/ Valve Air Control Moulds & temp.
Controller (MTC), Chillers, Hydraulic Core Operated Moulds and all equipment related Injection Moulding
Ultrasonic Welding Machine, 6 Axes Robotic Cutting and Welding Machine
ABS, AES, PP, HIPS, PVC, PBT, ACRYLIC, PC, PE, SAN, PS & Blend of PBT-PC & ABS-PC and TPE & TPO
High Precision and Hot Runner Moulds
Insert, Multi Core Actuated, Three Plate, Double Cavity Door Trim, Gas and Hydraulic/ Valve Air Control Moulds (weight ranging from 1 ton to 20 tons)
Knowledge of Injection Molding machine and auxiliary equipment Selection criteria, Plant Setup, Shop Floor Lay outing.

Work Experience

Manager- Injection Molding & Processing Engineering
Since Dec 2005
Company Profile: Manufacturer of high quality automotive sealing systems and exterior products.
Job Profile:
Play a significant role in establishment of New Injection Molding Plant and Responsible for handling new injection molding plant setup at Rajasthan in machine layout finalization, machine specification finalization, machine installation, infrastructure development macro & micro level planning, Building team for different department like production, quality, mold maintenance, machine maintenance, HR Administration, dispatch and logistic.
Handling, Process Engineering, mould maintenance, QA and assembly & PPC to attain high productivity
Ensure that the Production has the necessary resources to meet business objectives and to participate in annual business planning and budgeting of the plant
To co-ordinate with both Engineering and Business Development in new product designs, coordinating customer requirements with manufacturing cost and feasibility
To plan and ensure adherence to preventive and predictive maintenance schedule and obtain highest degree of customer satisfaction
Initiating& ensure Valve, Kaizen, Poke Yoke, Suggestion, Teaching, Training activity for cost reduction.
Responsible for quality operations including creating systems and process implementation.
Making KPI's as per management guideline and monitoring the same.
Responsible to develop parts of different processes like painting, plastic molding, rubber, printing etc
Supplier Manufacturing Capability Assessment with prospective suppliers.
Cost reduction by localization & alternate sourcing.
Scan the technological developments in the injection molding and other manufacturing processes being used and facilitate introduction into the company systems
Setting up (from scratch) and managing entire operations with key focus on profitability by ensuring optimal utilization of resources
Leading all customer related queries and problem resolving at customer's end.
Provide support to marketing department for matters such as product costing, assembly costing, project implementation.
Accountable for the reduction in rejection rate by 15 to 20% in different product during generation & assembly like in Door Trim, Front Fender Lining, Rear Tray, Garnish Bumper A,B,C Pillar, Engine under cover, Splash Guard, etc. also performing deep analysis, Poke Yoke, Kaizen, elimination of Muda, fixing of different problem and defect
Shown per man hour productivity improvement by 20 % in Door Trim, Front Fender Lining, Rear Tray, Garnish Bumper A,B,C Pillar, Engine under cover, Splash Guard, etc. managing molding & assembly by changing layout, Process parameter improvement, improvement in mold, training & eliminating bottle necks from process
Deftly preparing operational budgets and ensuring adherence to the assembly shop & execution process
Developing new process concepts for production optimization, yield improvement and developing guidelines for the sequencing of manufacturing activities on the shop floor (SOP)
Monitoring the production status, procedures & systems followed in production to ensure compliance norms with desired quality and timely delivery of orders
Implementing TS 16949:2002; ISO 14001:2004, OHSAS 18001 & maintaining documentation
Leading the cross-functional teams in the department for smooth functioning of manufacturing process
Carrying out the following functions:
New product development Involvement in Technical Feasibility Check, Resource availability, Process Parameter development, Layout Finalisation,Critical Check Point in Drawing as per Customer Requirement, Trial, Event Execution ,Inspection as per customer requirement, Packing Finalization and mass production start up.
QAV steps audits
In-house line trials and smooth mass production preparedness
Process improvement, innovation and Kaizen for Continual Parameter Improvement based on Theory & assembly line improvement by incorporating Poke Yoke, small Kaizen and eliminating Muda from process
Machine loading plan finalization
T0, T1, T2, Dhankaku, Hinkaku, Ryokaku & Ryoshi trial at local and abroad
Assembly and 6-axis robotic cutting for door trim and trunk lining of 4-wheeler
Examining the following:
Drawing and recognizing critical points & their solution with check point
Analysis of mould flow report for molding Parameter reference, gate location, minimizing molding defect & design limitation of product and understanding flow behavior of melted polymer inside the mold
Participating in development and implementation of long range production strategies
Ascertaining that the quality control plan is in place and effective
Accountable for timely procurement of man, material and machine resources for new businesses
Finalizing the machine and its specifications
Evaluating the machine capacity on yearly & monthly basis
Maintaining Door Lining Assembly Process with Ultrasonic Welding Machine
Managing the logistics and store activities partially

Highlights:
Successfully visited the following to attain high productivity:
Thailand for successful development of Door Lining Assembly Process with Ultrasonic Welding Machine for Jazz (HSCI) in cooperation with Nissen Chemitech Thailand
Shri Devi Tools, Mumbai for development and establishment of Rear Bumper Garnish for Honda City
Taiwan and China for development & shipping evaluation of 3rd & 4rth Generation City, Jazz, Brio and Amaze Door Trim, Front Fender,A,B,C Pillar moulds
Holds the merit of attaining all QAV Audits for new product development of City, Jazz and Brio
Major Products Processed for:
Honda (City , Jazz , Brio & Amaze) and Maruti
Front Rear Door Trim(Pocket, Arm Rest, Switch Panel,P/W Cover)
Trunk Lining
Front & Rear Fenders
Rear Tray, Front & Centre Splash Guards
Car Seat Part(Rear Seat Side Garn, Handle Height Adjuster, Handle Knob etc)
Foot Covers,
Garnish Rear Bumper
A,B & C Pillars
Jack Panel
Seat Parts
Panel Cluster Meter
Air Out Let
Hood Parts
Trim Tail End and Bumper
Body Side Molding (Door Protector)
LG and Samsung:
White Goods like TV & Computer Cabinets, Refrigerator and Air Conditioner Moulded Parts
Door Trim Assembly By Kimikomi & Welding Process for Jazz,City,Brio &Amaze

Dec 2004 to Dec 2005
Assistant Manager
Company Profile: Manufacturer of Refrigerators, Air conditioner, Washing Machines.
Job Profile:
Responsible for development and execution of production techniques and process flow
Ensured the following:
Scrap and waste reduction
Poor quality of waste and saved the time as well
Developed Std. Moulding Condition (SMC) through continuous improvement in the process
Organized various training programs for employee gradation and updation on latest version
Carried out trial for M/c, mould, material, masterbatches, etc.

Senior Engineer- Production
Nov 2001 to Dec 2004
Company Profile: Motherson Advance Polymers.

Engineer- Production
Aug 1998 to Oct 2001
Company Profile: The Supreme Industries Ltd.

Core Competencies:
Production Operations
Spearheading production related tasks including planning, control & troubleshooting for achieving the planned periodic schedules and process control
Developing new process concepts for production optimization, yield improvement and developing guidelines for the sequencing of manufacturing activities.
Knowledge of all Production Technique like JIT System, KAIZEN, 5's, PokeYoke, KYT, VA/VE, Bottle Neck Identification & Line Balancing ,Single Pieces flow, Muda identification & Elimination, product process lay out, Time study, SWCT, order combination method.
Process Improvement
Supervising process related tasks including planning, control & troubleshooting, material planning, etc. for achieving the planned periodic schedules and process
Developing new process concepts for production optimization, yield improvement and developing guidelines for the sequencing of manufacturing activities.
Knowledge of Process Engineering activity DOEs, Mould Flow Report Analysis, Scientific Injection Molding, Continual Improvements, 5 Pillar & 3 Consistency of injection Molding.
Project Management
Planning project activities, working out various requirements & monitoring overall operations for ensuring its timely completion
Coordinating projects activities and ensuring effective utilization & deployment of available resources
Product Development
Involvement in New Product development with respect to cost ,resource deployment, time over-run, quality compliance, process and layout
Coordinating the entire product development including requirement analysis, finalising parts specifications, designing, verification & validation, etc.

Future Goals

To become a General Manager.