Ref. No. : CA - 15050 - (Production - Moulding – with 28.8 years in Plastic Industry)

Education

Bachelor In Engineering - (Mechanical) from Jamia Millia Islamia University, New Delhi (Full time-evening classes) 2006- Passed with 1st division

Diploma In Mechanical Engineering
(Three year course specialization in Production) P. M. V. Polytechnic, Mathura, UP Board of Technical Education (Full time) 1997, Passed with 1st division

Skill Sets

Injection moulding, Blow Moulding, Extrusion, Assembly, Product Development, molding.
Technically sound professional with 17yrs years track record of delivering consistent results in ,injection moulding, blow moulding, Gas assist moulding ,extrusion ,thermoforming, power press, ,ppc ,assembly & packaging fields. Currently responsibility for driving innovation and improving production methods resulting in enhanced efficiencies and cost effectiveness for the company. 

Work Experience

Summary
Comprehensive knowledge of plastics material properties, processing options, limitations, and  considerations plastic injection molding operation, high precision mould, hot runner molds with multi core operations, Three Plate, Single Cavity/Double Cavity Door Trim ,Fender Lining, Gas and Hydraulic/ Valve Air Control Moulds, DOE and mold flow analysis of plastic injection molding components.
Good knowledge of  Business Management practices & Standards such as TS/ISO 16949,ISO 14001, OHSAS 18001 , Lean Manufacturing, Shop Floor Management tools, JIT System, KAIZEN, 5's, Poke Yoke, KYT, VA/VE, Bottle Neck Identification & Line Balancing ,Single Pieces flow, Muda identification & Elimination, product process lay out, Time study ,SWCT, order combination method, APQP, PPAP, MSA, FMEA etc.
Initiate management review and report the key performance index on customer concerns, corrective & preventive action and trends for improvement.
Experienced in establishing plastic processing & manufacturing plant, process stabilization, product planning, quality control, assignments, team building, Process Engineering and co-ordination with internal/ external departments
Possesses skills in managing overall production operations & ensuring accomplishment of pre-set production targets within stipulated time as well as cost parameters 
Exposure in assessing the training needs of the various employees in co-ordination with the various department heads in the respective departments.
 
TECHNICAL EXPERTISE
Injection Moulding Machine
60 to 2500 Ton
All Electric, Servo Based , Hydraulic, Toggle 
Make Mitsubishi, JSW, Toyo, Toshiba, MIKI, Windsor, Super & Jet Master, EBM MACHINE-Speedex, FANUC and L&T.
Experience of Screw selection , Plasticizing capacity/Rate, Injection speed, Swept volume, Dry cycle time, melt temperature, melt viscosity, injection speed, injection follow-up pressure, switch over point from speed to pressure, cycle time. Cooling Time,Injecton pressure,Metreing  Stroke, clamping force etc
Knowledge machine selection criteria.
Raw Material
ABS,AES, PP, HIPS, PVC, PBT, ACRYLIC, PC, PE, SAN, PS & Blend of PBT-PC & ABS-PC and TPE & TPO  and Rubber
Commodity, engineering Plastics and plastic Bland
Mould Handled
Gas Assist Moulding of Batten field & Gain (USA)
Cold Runner, Hot Runner, Hydraulic/ Valve Air Control Moulds & gas assisted moulds.
High Precision mould with multi core actuated, Insert Mould, Three Plate Mould, and Hydraulic Core Operated Moulds.
Single & Double Cavity Door Trim & Double Cavity Front Fender Lining.
Mould weight ranging from 1 ton to 20 tons.
Auxiliary Equipment
Mould Temperature Controller (MTC), Chillers, Raw material Loader, Volumetric mixer, Air valve controller and all equipment related Injection Moulding
Plastic Product Assembly Equipment/Process
Automatic Ultrasonic Welding Machine, 6 Axes Robotic Cutting ,6 Axes Robotic Welding Machine, Manual U/S Welding machine, Electric Screw Driver, Profile cutting m/c, Riveting m/c ,Stapling m/c .
Door Trim Assembly By Kimikomi (Cloth Pasting)& Welding  Process for Jazz,City,Brio &Amaze
Single Shot and Integrated Door Assembly.
Child Part/BOP assembly on Plastic Product Like Clip,cushion,DA tape,seal,foam,adhesive,stapling,acoustic application, switch, screw assembly, fabric application,riveting,stapler pin application, adhesive application etc 
Knowledge of Complete Door Trim Assembly Line setup By Kimikomi & Welding Process (InjectionMolding,Adhessive Application,Curing,Pressing, manual & auto welding, Screwing of mirror-window Switch-Panel-Arm Rest-Protector, acoustic  felt Application) 
Processing Expertise & Process Engineering
Strong processing knowledge of all type plastic Raw Material & moulds.
Processing Knowledge of gas assisted moulds.
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 mould.
Execute experiments (DOEs) to optimize manufacturing process performance.
Experience of Hot runner, Cold runner, Air valve, single/multi cavity Mould/Tool Process Development.
Experience of mould/tool assembly & maintenance.
Identification of critical spare parts.
Standardization of mold parts to reduce mold changeover time.
New product development Involvement in RFQ,Technical Feasibility Check, Resource availability, Process Parameter  development,QAV audits Layout Finalisation,Critical Check Point in Drawing as per Customer Requirement, Trial, Event Execution ,assembly tool/jig Development, Inspection as per customer requirement,APQP,FMEA,PPAP,MSA,SPC, Packing Finalization and mass production startup.  
       Other
Knowledge of Injection Molding machine and auxiliary equipment Selection criteria ,Plant Setup, Shop Floor Lay outing 
Standardization of product and raw material as per machine to reduce product changeover time and rejection.


MOULDED PRODUCT:
Interior Parts: 
Front & Rear Door Trim (Single & Double Cavity)
 Molded Door Assembly Parts (Pockets, Arm Rest Panel & cover, Switch Panel, P/W switch Cover etc)
 Seat Part (Rear Seat Side Garn, Seat Back Cover, Handle Height Adjuster, Handle Knob etc)
 Upper/Lower Pillars (Front, Centre& Rear), Rear Tray, Trunk Lining, Jack Panel, Panel Meter Cluster 

Exterior, Under Body & Under Bonnet  Parts
Bumper, Bumper Garnish, Fog Lamp Cover, Front/Rear Fender (Single & Double Cavity), Splash Guard, Door Protector (Body Side Molding), Trim Tail End, Qtr Window Garnish, Sash, Window Partition,Strak Front, Cover Corner, Front Grill Radiator, Foot Covers, Duct Cooling, Air Outlet, Duct AC intake, Hood Parts, Roof Pads, Cover STRG Joint etc.

ASSEMBLY PRODUCT:
Door Trim: Single Shot & Integrated Door Trim Assembly.
Integrated Door Trim Assembly by Kimikomi Process (Cloth Pasting), Welding, Screwing, Acoustic felt Pasting.
Single Shot Door Trim Assembly by Profile Cutting, Welding, Screwing, and Acoustic felt Pasting.
Front Fender Assembly: Riveting, Stapling, Sus nut application
Engine under Cover: Screwing, Sus Nut, Push Nut Application.
Rear Tray: Acoustic Felt welding, Clip Assembly.
Trunk Lining: Profile Cutting, Acoustic Felt Application, Clip.
Window switch Assembly :Sub,Mass,mirror etc








CORE COMPETENCIES




Production Operations
Manage the inventory at the Plant effectively aim towards maximizing the inventory turns & reduce the inventory carrying cost by effective planning. 
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.

Product Development/ Process Improvement 
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.
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,   



Assist.Manager Manufacturing - Plastic Injection Moulding Operation & Assembly
March 2014 till date

Key Result Areas:
Responsible for policies and procedures, training supervisors and administrators, maintaining a production schedule, giving performance reviews and motivating staff to meet production goals.
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 by recruitment & Training 
To co-ordinate with both Engineering and Business Development in new product development, coordinating customer requirements with manufacturing cost and feasibility
Initiating& ensure VA/VE , KAIZEN, Poke Yoke, Suggestion, Teaching, Training activity for cost reduction 
To ensure reductions in scrap cost, in- process wastage cost, maintenance cost, Energy cost, etc by identifying bottle necks from process & make action plan for eliminating the same
To identify and prioritize tasks and activities involved in the day to day operations of the plant.
Responsible to develop parts of different processes like painting, printing etc.
Leading all customer related queries and problem resolving at customer's end.
Developing new process concepts for production optimization, yield improvement and developing guidelines for the sequencing of manufacturing activities on the shop floor (SOP)
Making KPI's as per management guideline and monitoring the same.
Accountable for timely procurement of man, material and machine resources for new businesses
Maintain reliable and safe manufacturing systems while improving production rates, efficiencies, yields, costs and changeovers.
Support process change activities through Change Management system.
Assist with shop floor activities (changeovers, equipment breakdown resolution) that arise from or are causing and adverse supply condition towards the customer.
Finalizing the Injection Moulding machine specifications as per product requirement.
Maintaining Door Lining Assembly Process with Ultrasonic Welding and Robotic Cutting machine.
Holds the merit of attaining all QAV Audits for new product development of City, Jazz, Brio, and Amaze & Mobillo.
Carrying out the following functions:
Working as active member of cross functional team for new product development
New product development Involvement in Technical Feasibility Check, ECN/PCR implementation,CRF generation, Resource availability, Process Parameter  development, Layout Finalization, Critical Check Point in Drawing as per Customer Requirement, QAV steps audits Trial, Event Execution ,Inspection as per customer requirement, Packing Finalization and mass production startup
In-house line trials, abroad trial, 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
Process Parameter Optimization, Parameter verification, Parameter validation and Trouble Shooting. 
T0, T1, T2, Dhankaku, Hinkaku, Ryokaku & Ryoshi trial.
Assembly and 6-axis robotic cutting for door trim and trunk lining. 

Achievments
Successful development and shipment of door Trim, Front-Rear Fender, Rear Tray, A,B,C Pillar and Bumper Garnish of City ,Jazz, Mobillo, Brio & Amaze from China and Taiwan.
50% Productivity improvement in Door Trim assembly by eliminating MUDA, line balancing and order combination method.
50% Productivity improvement in Fr.Fender assembly by elimination of MUDA and line balancing method.
Successful Development and startup of Brio, Amaze,3rd  & 4th Generation City Moulds
Generation of space by restructuring of Finish goods store as per daily distribution of customer demand.
Significant role in establishment of New Injection Molding Plant and Machine at Pathredi Rajasthan in 2014 .



Manager- Injection Moulding, assembly & extrusion
Feb 2013 – March 2014          
Company Profile: Mfgr of consumer goods, Home appliances like washing m/c ,Juicer mixer, Refrigerator etc
Job Profile:                                             Product line –Consumer goods, Home appliances like washing m/c ,Juicer mixer, Refrigerator etc, snack table , cargoz , extruded products, wind screens, ballistic items like PC lathi, FRP helmet, Bullet proof helmet,  PC shield, light engineering product, etc.

Achievements
Development and implementation of Multi-layer Sheet with Extrusion and Main door liner with thermoforming setup.
Got the best employee award in Jan 2014. 
Implementation of ISO 9000:2000.
Development and implementation of Riot Control Equipment with Injection Moulding and Thermoforming setup.
Development and implementation of Bullet Proof Jacket and Helmet Production with compression Moulding setup.
Implementation of SAP (PP) Module.
Development and implementation of Snacks Table (Railway) with Injection Moulding setup.
Development and implementation of Poly Carbonate Plain and Textured Sheet with Extrusion setup.
Other (Project)
Successfully customization & implementation of SAP PP module as a project leader.
Successfully handling of new developments.
Snacks Table (replacement of conventional metallic table with PC table)
Multilayer extruded sheet & profiles for refrigerated Industry.
Refrigerator metallic parts redesigning and assembly. 
Poly carbonate Shield for Police (Replaced with conventional Cane shield)
Poly Carbonate Arc chamber covers for GEIS




Plant  Incharge                                         Feb 2002- Feb 2013      
Company Name: Moser Baer India Ltd
Product line- Soler laltain and its parts ,Junction box ,Container , Emerging products , USB Drive , Recordable & Rewritable CDs, Pre-recorded,DVDs and  its different type of boxes . 
Job Profile:
Responsible for total operations with accountability for Production Targets, meeting Delivery Date, Productivity, Quality, Manpower management and cost control.
Responsible to develop and execute Production Plan and ensuring production at optimum capacity 
Organizing Periodic Review of Production Targets, achievements, deviations and preparation of corrective action plan; using statistical tools / techniques to impact on process for improvements.
Rejection control and resolve daily production problem.
Coordination among shop floor activities, Handling Assembly, Maintenance, PPC, Improvement Projects, Customer Co-ordination, and Strong Technical Capabilities.
Ensure discipline at shop floor, quality ,House Keeping and 5-S concept
Focused approach toward continual improvement in terms of Productivity, Quality cost and delivery, by plan, action and   periodic review
Responsible for inventory control ,management & procurement.
Ensuring compliance with International production standards:
5-S, FMEA and GRA standards.
 Achieving monthly KAIZEN targets.
Handled the following projects through DMAIC approach under Green Belt:
Under C. E. P.
Weight reduction in different types of CD & DVD boxes.
Introduction of reprocess material in different products.
Cycle time reduction in different types of CD & DVD boxes.
Under S. M. E. D.
Mould loading time reduction.
Colour change time reduction in pentone CD & DVD covers for export orders.
Curing time reduction of pallets of different types of CD & DVD covers.








Material processed: HIPS, GPPS ,Zylone ,Nylone ,PMMA,ABS, PP and PC. 
Machines/ Tools handled: Various Japanese & Koreans machines used for Injection Moulding, powe press , Packaging, Robots, Assemblers, Hot runner & different types moulds, Vacuum units, DCN, Hot Runner Controller and Automatic Material Feeding Systems, extruders.

Shift Incharge                                           Nov 1997- Feb 2002
Company Profile: Calcom Vision Ltd
Product line- Colour & B/w Televisions, deflection and wound components, power invertors, Home appliance ,automobile parts , stationary parts, contract manufacturing and plastic moulding.
Clients-  BPL, Philips, Onida, Videocon, Sansui, Samsung, LG & Akai.
Machines/ Tools handled: Taiwan CNC Injection Moulding Machine ,extrusion, assemblers, robots, power press.
Materials Processed: PPO, PBT, ABS, HIPS, GPPS, PP ,HDPE, LDPE , Polycarbonate, etc.

Future Goals

To be a managerial assignment in Plastic industry.

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