Ref. No. : CA - 15542 - (Production - Moulding – with 23.7 years in Plastic Industry)

Education

Diploma in Mechanical Engineering from Govt. Polytechnic, Chamarajanagar, Karnataka in the year 2000

Skill Sets

A dynamic and result oriented professional with over 14 years of in depth experience in Injection Moulding and allied Operations in Production, Processing, Mould , V&A , Production Quality Control and Inventory management activities in plastic industry. Along with this experience in New Product & project execution for shorter period of 1 year.

Work Experience

Projects Senior Engineer: Since Jan 2014
Senior Engineer – Operations: July 2007 to Jan 2014
Company Profile: complete in-house facility from moulding to assembly of final products including Eighty Plastic moulding machines plant and the capacity ranges from 40 ton to 350 tons of injection moulding machines from Sumitomo, Fanuc, Ferromatic Milacron ,Engel, Krauss Maffei 2k Injection Moulding along with fully automated robots like Yushin, ABB, Engel, Wittmann etc.
Job Profile:
Responsible for Vendor development
Responsible for proper execution of programme through proper planning of basic requirements.
Responsible for CPK of new tools & smooth ramp up.
Process Analysis and improvements to control rejection, machine and mould failures.
Working with cross functional teams to identify process improvement / re- engineering opportunities.
Drive initial trails of all new moulds.
Under take leadership to improve product quality and reduce cycle time.
Ensures regular audits on systems, operations and products are conducted to check conformance to set standards.
Initiate raw material changes & mould modifications to optimise input material cost.
Responsible for Daily production activities of Plastic moulding shop.
Accountable for maintaining quality systems, documents & records regarding ISO 9001 – 2000 & ISO 14001.
Projects to reduce the cost of production with respect to Quality Norms.
Managing and practicing safety, health & environmental related norms.
Process Analysis and improvements to control rejection, machine and mould failures.
Working with cross functional teams to identify process improvement / re- engineering opportunities.
Leads the cross functional team to drive initial trails of all new moulds.
Responsible for smooth ramp up of new moulds until mass production stage.
Under take leadership to improve product quality and reduce cycle time.
Ensures regular audits on systems, operations and products are conducted to check conformance to set standards.
Initiate raw material changes & mould modifications to optimise input material cost.

Achievements
Successfully established 5 projects.
Efficiently improved product reliability, quality index through process, mould modification.
Visited china several times to evaluate the new moulds.
Successfully established IMD & Insert Moulding technology first time in Chennai Plant.
Successfully established 2k Moulding and Baby Plast Technologies.
Won the Nakshatra Award to eliminate the rejections in 2k Moulding in which we was faced huge rejections initially.
Hold the credit for rejection control through mould modification.
Efficiently improved product reliability, quality index through process, mould modification as well as raw material change.
Hold the credit for cycle time reductions in various projects by optimizing.
More than 10% savings in indirect labour through process automation.
Visited twice to China for validating and approving the new tools.

Projects
Productivity improvement up to 30% in 2k moulding.
Up to 20% productivity improvement by modifying grippers and insert fixtures.

Executive- Injection Moulding
July 2004 to July 2007
Company Profile: Manufacturer of more than 1400 and products include Colour Television, Washing M/C, DVD, Microwave, Air Conditioner etc. It’s Plastic Moulding has 8 Nos. mid size Moulding m/c. (JSW- All Electric./ Hydraulic) & one JSW –1600 T, all m/c fitted with Robo (Yushin) & Chiller (Reikin) with Gas Preparation unit ( Production capacity of 13000 Shots / day).
Job Profile:
Successfully handling production operations for production of 1.5 million CTV LCD & LED sets and effectively handled injection molding operations.
Managing production planning and operations at plant with a view to ensure timely accomplishment of production targets within the time and cost parameters.
Tracking daily production & consumption of raw material, coordinating with top management. procurement based on consumption.
Effectuating cost saving initiatives, achieving cost reduction through value engineering, reduction in breakdown, rework and waste elimination.
Conceptualized and implemented measures for enhance operational efficiency and optimize resource and man/machine utilization and achieved
More than 25% increase in productivity.
20% increase in productivity of the cabinets by designing Mixing nozzle
More than 10% savings in indirect labour through process automation.
Played a key role as a team member in execution of Six- Sigma projects and achieved
12500 PPM to 2500 PPM reduction in moulding & painted cabinet rejection rate
Up to 20% increase in O.E.E
210 Min to < 90 min mould change time reduction
Up to 5% reduction of power consumption.
Developed jigs, fixtures & moulds as per predefined specifications and carried out testing/ inspection of jigs & fixtures, to identify and rectify defects.
Ensured adherence to Safety, Environment and Health standards in all functional areas and developed & implemented measures for enhancing safety levels.
Implemented measures for continuous improvement in process capabilities and ensured complete in-process quality control and adherence to ISO: 9001 and ISO 14001 norms.

Equipment & Systems Handled
Mid size Moulding machines (JSW- 850 T - All Electric / Hydraulic), JSW -1600 T, all m/cs fitted with Robo (Yushin) & Chiller (Reiken), Production capacity of 13000 Shots / Day.
Centralized Gas Preparation unit – Capacity – 7500 Shots / Day
Steam Assisted Paint free moulding set up for LCD/LED panels – Capacity - 4000 Shots / Day.
Paint shop consisting of 4 lines & equipped to do 2 & 3 colour painting & UV Painting.
Thermocoal moulding process – having 4 Kurtz m/cs fitted with Fire tube Boiler, Compressor, and Pre expander.

Assistant Engineer
2002 –2004
Company Name: Perfect Power Controls
Job Profile:
Gained hands on experience in handling the operations of JSW & Krauss Maffei Injection Moulding machines ranging from 110 tonnes to 300 tonnes with Robot handled .
Played a key role in implementing TPM in model machine as the core team Leader.
Successfully implemented process modifications to reduce the mould start up time and mould change time to the level of world class standard.
Equipment & Systems Handled
JSW & Windsor Injection Moulding machines
Electric Servo & Hydraulic Drive machines.

Apprentice & Company Trainee
2000 –2002
Company Name: TAFE LTD
Job Profile:
Gained hands on experience in handling the operations of JSW & Krauss Maffei Injection Moulding machines ranging from 110 tons to 300 tons with Robot handled.
Played a key role in implementing TPM in model machine as the core team Leader.
Successfully implemented process modifications to reduce the mould start up time and mould change time to the level of world class standard.
Equipment & Systems Handled
JSW & Windsor Injection Moulding machines
Electric Servo & Hydraulic Drive machines.

Training and Development
Six Sigma – Green Belt Training 2 day training.
World class manufacturing system
Performance management
One Day Training on ISO 9000-2000
One Day Training on Effective Time management
One Day Training on 7 QC Tools
Basics of Plastics at Central Institute of Plastic Engineering & Technology, Chennai

Core Competencies
Expertise in implementing the processes that will enable organization to consistently meet and enhance customer satisfaction.
Comprehensive understanding and knowledge about quality standards. Proficient in implementation of techniques like for improving the operational efficiency and achieving cost savings.
Core competency to meet pre set production targets, conceptualizing and implementing process modifications to enhance operational efficiency and optimize resource utilization.
Expertise in Injection Moulding production and rich hands on experience in processing wide range of materials viz., PMMA, PC, ABS, PP, PE, Nylon, HIPS, Filled Nylon, Poly Acetals,
Proven expertise in striking cross-functional coordination and achieving operational synergies to achive pre set production targets.
A keen strategist with skills in team building, and proven abilities in liaising and troubleshooting.
An excellent man-manager with proven strengths to maintaining harmonious labor relations to enhance overall productivity.
In depth knowledge of various Injection Moulding processes like, Conventional, Gas assisted, Steam assisted moulding, 2k Moulding .
Developing an integrated management system for meeting the standard requirements of ISO-9001, QS-9000, & ISO-14001 quality standards.
Implementation of mould & machine history card for monitoring of CTQ’s (Critical to Quality) & machine failures in manufacturing process to ensure long working period of mould & machine.
Conducting of Internal Audits periodically to assess the status of running Process and to take corrective action for achieving organizational objectives.
Assisting New mould developments, validation of new moulds at vendor end & new vendor development.
Initiating continual improvement projects, Kaizen, 5S & workplace management.


Future Goals

To succeed in an environment of growth and excellence and earn a job which provides me job Satisfaction and self development and help me achieve personal as well as organization goals.

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