Ref. No. : CA - 27642 - (Production - Moulding – with 23.7 years in Plastic Industry)

Education

MBA From IASE Deemed University Rajasthan in 2011

IIP, PG Diploma in Packaging Technology, From Mumbai (Distance Learning) in 2011

PG Diploma in Plastics Technology, CIPET, Lucknow in 1999

B.Sc. From Magadh University, Bodh Gaya, Chemistry Honor in 1996

Skill Sets

Manufacturing Operation @ Plastic Injection & Blow Moulding, Sheet metal stamping, Production planning & Control, Plastic tool development & Review
Engineering & Process Excellence, Lean manufacturing, Standards & Procedure development, Cost Control / Optimization, Capacity Enhancement
Supply chain coordination, Vendor Management, Quality assurance, Project management, People Management , Training and Development

Work Experience

Head Part Production Operation (Deputy Manager)
Since Jan 2017
Company Profile: Leading manufacturer for automotive product to all most all Automotive OEMs.
Job Profile :
Productivity Improvement by 20% - 50% (Cost Impact INR 35 lac/Anum) plastic molded products by
Cycle time optimization @ In-house and Supplier and save more than 1500 Machine Hours
Process / Mould Improvement (Auto De-gating system & Runner/ Sprue Bush Modification)
Robotics & Advance Hi-Speed Machine & Raw Material & Additives
Productivity Improvement in Sheet Metal stamping by 10% through development of progressive tools.
Yield Improvement plastic products from 67% to 78% @ target 80% through reduction in sprue runner length, Use of Hot Sprue bush, Hot Runner System & also merging low weight product with higher weight product of same RM.
Yield Improvement Sheet metal stamping product by 7%.
Man Power Reduction through Development of 4 in 1 module in Molding Shop Floor through Automation viz. Robot / Sprue Picker / Sprue Separator Conveyor & Mold modification (Auto De gating).
Energy saving projects tracking & improvement in Injection molding machine hot air Dryer to save energy of 15 Lac/Annually.
Created a Lean Culture by incorporating Visual Management Systems viz. Shop Floor Lay out Review / Modification for Single Line Flow of child Parts that minimize material movement & Developed Supper Market Model of child Parts for production which assembly line loss by 18%.
Identifying and transitioning work to outsourced vendor, reducing total manufacturing costs by 30%.
Replaced labor-intense processes while simultaneously enhancing workflow through new technology that save man Hours by in Testing Trimming operation of Connectors.
Establish plating process of new development sheet metal stamping parts parts.
Implement / Established Tool safety for Sheet metal stamping process.

Manager Production Operation/Tool Maintenance/ IPQC
Nov 2015 to Dec 2016
Company Profile : Leading manufacturer of Automotive Lighting, Interior Lighting, Taxi Roof Lamp.
Job Profile :
Productivity improvement by 15% & Warpage control within ± 0.5 mm of 14 mm thick light guide of Volvo SIL Lens & Reflector through development of cooling fixture.
Successfully completed project of Porsche 14 mm thick light guide SIL & Qualify JLRQ.
Implemented condition monitoring & predictive maintenance of critical mould parts and took corrective actions to avoid breakdown. Designing and implementing appropriate systems preventive maintenance, Mould history and asset register. Preparation and control of annual tool maintenance budgets & Mould maintenance cost reduction by 10%.Consumable item consumption reduction by 5% in Production department.

Asst Manager Production Operation & VA/VE
Nov 2013 to Nov 2015
Company Name : Ecorea & Kuroda Electric India Pvt.
Ltd.
Company Profile : Manufacturer of Injection molded automotive & electronic consumer white good plastic products for Automotive OEMs viz. Nissan, Toyota, Yazaki & Electronic Consumer goods OEMs. – Viz. LG, Sharp, Brandenburg, Jabil etc.
Job Profile :
Improve In house Rejection from 6% to 2.5% through continuous improvement activity viz. startup rejection reduction by improving process repeat-ability, restructure team, developing fixture to simplify work, standardize work process etc. & Succeeded in reducing assembly idle percentage from 1.6% to 0.3% through LOB & streamlined component flow.
Successfully handle Assembly Line production.
Coordinate in installation and commissioning of 03 Injection molding machine under plant expansion project and conduct new and existing mold trials for customer.
Productivity Improved by 8% through process optimization & robot optimization, breakdown reduction.
Reduced overall facility downtime by 10 % by improvement project on Mold change over time reduction, Machine setup time reduction and reduction of break down time due to spare availability and tools breakdown.
Implement close loop system to utilize maximum reuse of material consumption with product quality constraints.
Improve product handling rejection through introduction of product based packaging Trolley & PP Box.

Asst Manager (Engineering & Development New Project) : Apr 2009 to Oct 2013
Sr. Engg - Inj. Moulding & Packaging/ Palletizing : Apr 2005 to Apr 2009
Engineer -Inj. Moulding & Packaging/Palletizing : Nov 2001 to Apr 2005
Company Name : Moser Baer (I) Ltd.
Company Profile : Manufacturer of Storage Media (CD-R, DVD-R), Solid state media (Pen Drive), Photovoltaic Solar Panels, LED lighting, Solar lantern lighting having state of the art manufacturing molding plant.
Job Profile :
Restructured In-house existing resource for Plastic Junction box solar panel & LED lighting & Pen Drive product projects, Development & Procurement of Moulds & Ancillaries Equipment, Conduct trials and established process at molding and assembly for smooth production with project tracking & monitoring.
Reduced cycle time for productivity enhancement (15%) without compromising on quality and started continuous improvement activity through regular monitoring of cycle times and raw material consumption, down time analysis and reduction.
Cost saving projects DMAIC methodology (Six Sigma) – through raw material saving through consumption reduction by reducing weight & Low cost alternate material utilization, Master batch consumption reduction.
Played a pivotal role in development of packaging like - Rigid injection molded plastic cases / boxes. Different types of printed corrugated master cartoon / product display Trays / LDPE monolayer stretch wrapping film / LLDPE cast film. Wooden pallet, Palletization, container stuffing (as tertiary packaging) as per legal & customer.
Zero injuries & lost time (2009) safety audit report.
Utilized packaging setup for the dispatch of Retail & bulk pack to DTA & export customer.
Awarded Best Employee award (2007) & Best appreciation KAIZEN awards (2005).
Achieved success in implementing Autonomous Maintenance pillar of TPM on shop floor as team member.

Trainee / Shift Engineer
Company Name : Mag Filter & Equipment Pvt. Ltd
Company Profile : Suppliers of Automotive filter, Logo, other exterior and interior plastic components

Key Deliverable
Manufacturing Operation / Production Planning & Control / Quality / People Management:-
Steer part production manufacturing operation and directly managing / responsible for output of a team containing Assistant managers (Max 02 Nos.), Supervisors & Engineers (Max 08 Nos.) & indirectly overseeing employees (Roll + Contract) in 3 shift production operation (60+ Nos.).
Direct management of work center PQCDSM and Development of strategic framework to led the team in delivering PQCDSM target & Implementation KPIs of Team members.
Established & Manage all daily operation viz. Capacity planning, Daily production plan & schedule, Staff & Labor requirement, Material control / Inventory control, Supply chain, availability of required resource (4M), Mfg. BEST practices viz. Kaizen / Quality circle, In process quality control, continuous improvement, employee training & development, employee grievances & providing timely resolutions on the same.
Identification of Key matrices to derive continuous improvement plan, Responsibility of Departmental P&L & OPEX budgets adherence.
Ensure composite reports viz. OEE, Gap analysis, CAPA/QPR, Carrying out analysis rendering solution and technical support to the team to reduced wastage and time loss. Proactively assist Plant management in a manner to meet agreed monthly compliance. Responsible for Management review meeting.
?Planning and effectuating maintenance for the machines & moulds. Preparation of plans & budget for reconditioning of existing tools to minimize MTTR & MTBF.
Manufacturing Operation / Production Planning & Control / Quality / People Management:-
Steer part production manufacturing operation and directly managing / responsible for output of a team containing Assistant managers (Max 02 Nos.), Supervisors & Engineers (Max 08 Nos.) & indirectly overseeing employees (Roll + Contract) in 3 shift production operation (60+ Nos.).
Direct management of work centre PQCDSM and Development of strategic framework to led the team in delivering PQCDSM target & Implementation KPIs of Team members.
Established & Manage all daily operation viz. Capacity planning, Daily production plan & schedule, Staff & Labor requirement, Material control / Inventory control, Supply chain, availability of required resource (4M), Mfg. BEST practices viz. Kaizen / Quality circle, In process quality control, continuous improvement, employee training & development, employee grievances & providing timely resolutions on the same.
Identification of Key matrices to derive continuous improvement plan, Responsibility of Departmental P&L & OPEX budgets adherence.
Ensure composite reports viz. OEE, Gap analysis, CAPA/QPR, Carrying out analysis rendering solution and technical support to the team to reduced wastage and time loss. Proactively assist Plant management in a manner to meet agreed monthly compliance. Responsible for Management review meeting.
Planning and effectuating maintenance for the machines & moulds. Preparation of plans & budget for reconditioning of existing tools to minimize MTTR & MTBF.

Process Excellence / Manufacturing Engineering :-
Mould Flow & Design Review & Scientific molding or
Process Engineering for New tool development & existing tool trouble shooting.
Researched & Updating latest Technologies regard Injection molding machine & Moulds, Established standard for Mould Cavity Optimization & Utilization, Tool Trials & Validation, Purchasing of Injection molding machine & Mould, Process Variation reduction, raise Capex, justify purchase with ROI.
Plan and execute Plant equipment rearrangement for streamlined process flow / Shop floor layout optimization
Deployment of BEST activity viz. Kaizen, QC, 5’S, CFT for Automation project in molding, Cost Reduction & shop floor Improvement.
Established and employed LSS methods (Lean manufacturing & Six Sigma) & carrying out time & method study, Man / Machine efficiency study to measure and maintain productivity and quality improvement processes, wastage reduction viz. cycle time reduction, scrap reduction, set up and change over time reduction,
Ensure the process capability of various machines and effectuating various energy saving programs.
Supervising / Coordinating entire product development cycle viz. requirement analysis, finalizing specifications, design review, Raw Material selection, prototype development & testing activities, Tool Trials, Packaging standard, BOM creation & ensuring smooth flow of material through optimized work place layout with approved PPAP documentation.

Vendor Development / Supplier Improvement :-
Auditing the vendor for technical up gradation, quality management system and achieving long term cost cut projects @ Plastic Injection Molded parts, Rubber Parts & Blow molded parts.

Packaging Technology :-
Manufacturing of Rigid Plastic Packaging product – Injection / Blow molded product, Tool trials & qualification, conducting detailed tests to evaluate quality & finalizing BOMs, MSS & updating database accordingly, review & upgrade packaging quality specification for better performance, matching according to standard design & specification based on customer or market inputs. Working on various cost optimization projects in Packaging through modification in primary & Bulk Packaging materials.


Operational Purview
Hand On experience :
Horizontal as we as Vertical Injection molding machine from 2000T to 10T (All Electric & Hydraulic system) of different make for Thermoplastic / Thermo set Plastic, Extrusion Blow molding machine up to 20 Ltr. Capacity Sheet Metal machine from 20T to 45T.
Post Molding Operation - Ultrasonic/Vibration Welding, Annealing, Buffing.

Auxiliary Equipment –
YUSIN & YUDO 2 axis / 3-6 axis Robot.
L&T motan material feeding system, Scrape Regrind Granulator & Annealing Chamber.
Different types of Hot runner controller
Water Chillier / MTC / Hot & cool system etc.

Processing of different Plastic raw material as well Sheet Metal Material (0.2 gm to 4 Kg)–
Thermoplastic PC, PC Glass filled, PC + ABS Alloy, PBT, GPPS, HIPS, SAN, ABS, PMM, POM, PPCP, PP-Glass filled, PP- Talk Filled, PPHP, HDPE, LDPE, EVA,PVC, PPE+PA (Xyron), Nylon6, Nylon66, Nylon Glass Filled 7% - 50%.
Injection molding Grade Phenol compound Thermoset.
Sheet Metal Low carbon steel, CRCA, Copper, Brass etc.

Product Range Exposure -
Automotive 2 Wheeler Switches and Handle Bar switches & 4 Wheeler Interior and exterior lighting Assemblies & Body Trim, Air Filter Assembly, Ducts & Tanks, Electrical Relay base body, lower/ Side Cover, 2 Wheelers Helmet & Other Accessories.
Electronic Consumer LCD Back cover & Front cover, AC Inlet Grill, Font Grill, Fan, Washing Machine Tub Outer, Tub Cover, Control panel, Refrigerator Veg. Tray, Water tank, Multi duct, Door End cap etc
Junction Box for PV Cell Module i.e. Casing, Cover, Fixing Part, Connector body male / female, Sleeve connector, Nut, Solar Lantern, LED Bulb & Tube Housing.LED Bulb, Pen Drive casing.
Packaging Products Jewel Box, Slim case, Cake Box, DVD Box, Thermoformed boxes / Trays, Trial, Qualification, Process setup of different types of moulds - Hot runner, Hot runner with cold tip, 2/3 Plate mould, Multi cavity Cold runner mould.
Work Exposure on Assembly Production & Line Balancing.
Have knowledge and exposure on Mold Flow, Creo / UG Nx8 design software, Minitab & MS office


Training & Certifications
Professional Training Accounting and Taxation from TAAP Pune.
ERP Production/Inventory module – RAMCO/ SAP.
Training in TPM, Six Sigma Yellow belt. Lean Mfg.
Train the trainer (2 day training) at MBIL etc.
1 Week Certificate course in Flexible Packaging at IIP Delhi (1 Week)
1 Week Certificate course in Pneumatics / Electro Pneumatics – SMC.
PFMEA, PPAP & APQP at MACE 2018

A Brief Overview
Experience in Plastic product production / manufacturing operations with educational background of Post Graduate Diploma in Plastic processing technology, Packaging technology & MBA Mkt.
The wealth of expertise comes from working across plastic Injection molding & Blow molding products manufacturing & Its Sub assembly in Electronic Consumer, Automotive & Rigid Plastic Packaging products.
I am adept in all facets of production operations, production planning, team building, cost optimization and quality improvement coupled with profound training and development skills.
Familiar with costing knowledge plastic, rubber, Sheet Metal parts & Tools.
Hand on experience of Operational / Capital expense budget control & use ERP (PP Module- SAP/RAMCO).
Having exposure to work in environment having ISO9001/EHS ISO 14001/OHSAS 18001 and IATF 16949:2016, Lean Manufacturing, TPM, KANBAN, Six Sigma DMAIC, DOE, 5’S tools etc.
Efficient organizer, communicator, motivator, team player and a decisive leader with the ability to motivate teams to excel & win with profound training and development skill.

Future Goals

Growth

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