Ref. No. : CA - 16818 - (Production - Moulding – with 30.2 years in Plastic Industry)

Education

MBA (Operation) from IGNOU, with 2nd Class.

PGD-Plastics from Central Institute of Plastics Engg & Technology from Lucknow.

B.Sc (PCM) from Utkal University with 1st class 




Skill Sets

Production planning
Head of operations

Work Experience

Sr. Manager-Molding
Dec 2014 to Present
Company Profile: Manufacturer of Auto Lighting products, LED Lights


Head Operation Prod./NPD/EHS/QA/MR
Aug 2011 to Nov 2014
Company Profile: Plastic Molding for Auto ancillaries, Rubbers, Activated Carbon Canister, HTC cord, Power steering tank, Vibration Welding, Customers include GM,Ford, Tata, MSIL, VW, BMW, FIAT.

Mgr Prod.Molding/PPC/EHS/ Paint shop production on Plastics.
Oct 2007 to July 2011
Company Name: Polyplastics Industries Pvt Ltd.
Company Profile: Plastics Auto components, Electroplating, Paint Shop, Vacuum metalizing, Auto components for MSIL, Ford, GM, Nissan, Renault, Tata, Eicher, Honda, HMSIL, Toyota, Hyundai etc

Asst. Mgr-QA/QMS/EHS 
Feb 2005 to Sep 2007
Company Name: Krishna Maruti Ltd
Company Profile: Plastics Door Trims for Maruti Cars, Plastics parts for MSIL, Honda and Suzuki.

Engr-II-Moulding/QA
Aug 1994 to Feb 2005
Company Name: Bharti Teletech Ltd
Company Profile: Beetel Telephone.Injection Molding of Telephone parts.

MY KEY SKILLS :        
(Production plastics Moulding)
My Skill Matrix 
•Man, M/c & material planning and control.
•Mould loading plan through mould loading matrix.
•Plant capacity analysis & improvement. No of m/c required for existing and forth coming business. 
•M/c utilization, molding efficiency & OEE.  M/c idle time analysis and improvement.
•Monthly raw material reconciliation and report. Scrap reduction.
•Training taken from AOTS, JAPAN on Toyota Production System, JIT and TPM. Implementation of 8 Pillars of TPM.
•Inventory control by the help of production cycle time and Takt time.
•Process optimization through Robust design Technique.(Inj. Speed~ apparent viscosity study).
•Trouble shooting and parameters optimization of Injection molding.
•Handling of Injection Molding M/c up to 1300 Tonnage.
•5-S and Visual management implementation in shop floor.
•Reduction of 7-waste. Implementation of 3K and 3R.Defect Analysis and improvement.
• Preparation of daily, Monthly & yearly production report.
• Automation, Autonomation and  KAIZEN. ITR, VAPCO, SMED, MY MACHINE  concept.
• QMS System implementation w.r.t ISO/TS16949 & ISO9001.
• ISO 14001/BS OHSAS 18001 system implementation (MR).
• Mould flow study for new mould through Pressure drop, cavity balancing and holding time study.
• Handling of Customers process audit, Internal audit, ISO/TS 16949 & EHS audit.
• Production schedule to meet daily delivery target.
• Driving work force through training, development and guidance.
• Demand, supply & profit relation graph.
• Cost reduction through Kaizen, War on waste, Quality Circle, Six Sigma & QIP.
• SMED, Reduction of mould change time. M/c Preventive & predictive maintenance.
• Control Plan, FMEA, PFC, PPAP, APQP, Timing plan, BMW Q-offer, VW-QTR & Dev. Activity.
• SPC (Statistical Process control). Electro Plating on ABS and Vacuum metalize process.
• Implementation of TPM,TQM, TPS and JIT. Assy, paint shop, Line balancing, RFT and pull system.
• PAINT SHOP HANDLING :- Handling of paint shop and Laquor shop.
• Paint Ratio Mixing, Paint Viscosity, Painting defects and trouble shooting.
• Masking, Paint gun and jig//Fixture maintenance.
• Line Balancing. Testing of painted parts. Productivity improvement.
QA/QMS/MR responsibility : (MR responsibility of ISO/TS16949 & SHE in Deltronix)


My Skill Mapping :-
MR Responsibility & QMS:-
• Working as  MR. Responsible for implementation of  ISO/TS-16949, ISO-9001, ISO-14001, OHSAS-18001.
• Preparing Quality Manual, Procedures, Standards/specification & other Engg documents as per ISO/TS16949 standards.
• Quality policy review with top management.
• Quality Objectives and Target setting.
• QMS & Business plan with Management.
• QMS documentation, document control & record keeping.

• Internal Audit plan, Adherence of IQA as per plan, CAPA for NCs and review through MRM.
• Handling ISO/TS16949 external audit.
• Training calendar for implementation of QMS. MIS Report.
Receipt Quality/Supplier quality Audit & development :-
• New Supplier selection and Q-Capability analysis and development.
• Preparation of Supplier Quality Manual.
• Supplier Audit plan and development.
• Preparation of In-coming Inspection standards(In-coming control plan).
• GRN ~ In-coming Inspection report ( Joint inspection report with supplier).
• 8-D reports from supplier in case of Non-conformity.
• Calculation of Supplier quality PPM, Lot acceptance rate, DOL & supplier performance grading.
• Meeting with supplier for Quality up-gradation (MOM). Supplier rating.
In- Process and Out going Quality :- 
• Preparation of control plan, PFMEA, PFC, In-process standards, Job cards & Job set up.
• Process Capability Study, MSA study, Periodic Inspection report.
• Work Instructions, Reference Sample Limit Sample,  Visual aids, Quality alert, skill matrix.
• Process & Product validation plan and reports.
• Final Inspection report, PDIR and dock audit.
• Daily & monthly rejection review and corrective/Preventive action. Daily quality meeting.
• Preparation of in-process rejection PPM, COPQ, COQ and 8-D reports.
• Periodic Testing plan for product reliability & Measuring instrument Calibration plan.
Plastic Testing (Reliability Test) :-
• MFI Test, Izod & charpy Impact Test, Tensile Strength Test, Flexural Strength Test, Rock well hardness, Ash Content, Glass content, ESCR, Drop Impact Test, Opacity Test, Di-Electric Strength, VST, HDT, Chemical resistance test, Burst Strength etc.
Customer Quality/Customer Audit/Customer complaint handling :-
• Working as a customer representative.
• Major customers are- GM, FORD,MSIL, Tata Motors, FIAT, Volk Wagen, BMW, Nissan, Renault, Honda, HMSI, Yamah,
• Quality system audit handling as per QSB (GM), Q1(Ford), VDA 6.3& 6.5(European automotive system) and improvement based on audit observations.
• Implementation of MMOG/LE (Material Management Operation Guide lines/Logistics Evaluation).
• Customer complaint handling, Field failure analysis and Submission of 8-D.
• Analysis of customer complaints, customer PPM and CAPA with target date.
• Data uploading in Ford & GM global web site.
• Attending Quality meeting at customer end. Communication of customer requirements to management and down the level. 
Complete customer satisfaction through team activity (Above the customer’s requirement) :-
• I have taken Training  at AOTS, Japan on TQM, TPM, TPS, JIT, Visual management, Kaizen & 5-S.
• My active participation in implementation of TPM & TQM in the organization. 
• Cost saving & reduction of 7-waste through Six-Sigma, Quality Circle, TCA, War on waste, ACT clusture, My machine concept, VAPCO, ITR,  Kaizen, 3K,3R and Automation.
• Philips Crossby’s 4-Absolutes of Quality, ZD concept, POC & PONC.
• Juran’ Triology. Quality Function deployment. Deming PDCA cycle.
• Singo’s SMED, My machine concept, POKA-YOKE & Source inspection, Cost of poor Quality, VA/VE, .
• Right First Time (RFT), Q-Index, Pull system, Voice of Customers.
• Implementation of 8-Pillars of TPM. Autonomous maintenance. 3K, 3R, Visual management, 5-S.


MY INVOLVEMENT IN NEW PRODUCT DEVELOMEPNT:-
My Skill Mapping :-
• Feasibility study, Timing Plan, BOM, Part costing, RFQ and contract sign off.
• Preparation & submission of Q-offer & QTR for BMW and Volks Wagen.
• APQP, FMEA, PFD, Control Plan, Inspection standard, SPC, MSA, ECN & dimension report.
• Jig fixture & gauge development for new product.
• Study of Engg drawing, Product validation, Process validation and corrective action plan.
• Preparation of customer capacity sheet, plant capacity analysis, Run rate & through put ratio study.
• Initial product & process audit as per VDA6.3 (European Automotive standards).
• Automation, Customer standards.
• Product Validation, Process validation & Line set up.
• Initial control plan, MSA, SPC study and mould trial run.
• Mould flow analysis through Robust design technique (Viscosity, Pressure drop, cavity balancing study).
• Customer handling during new part development & customer audit.
• PPAP submission.
TOOLS AND TECHNIQUES I KNOW :-
•7-Quality Tools for problem solving.
•5-S implementation in Shop floor.
•Process control through SPC, R-chart & X-bar Chart.
•Six-sigma project. MSA study.


INVOLVEMENT IN EMS-ISO14001 & BS OHSAS-18001 ACTIVITIES :- ( MR resp. in Deltronix)
My skill Map :-
•Working as MR for implementation of ISO 14001/BIS OHSAS 18001 in Deltronix.
•EHS policy, EHS objectives, Aspect~Impact analysis.
•Regulatory requirement as per Pollution control Act/rules and Factory act 1948.
•Training to all employees on EHS.
•EMP, OCP, Emergency Plan, EHS Manual, Hazardous                                                          waste handling & disposition.
•MR function, Internal audit, MRM, EHS certification audit.
•EHS documentation and system implementation as per standards.
•Various Testing for EHS compliance. Energy saving, Rain water harvesting, ETP/STP.
•Health and safety audit and improvement.

MY LEADERSHIP IN TEAM ACTIVITIES :-
•Quality Circle, Quality Improvement Project, War on waste.
•Six-Sigma Project. Team corrective action.
•Key Member in TQM & TPM practices. New part development.
TRAINING PROGRAME  I  ATTENDED :-
•TPM, TPS, JIT, TQM at AOTS-Japan.
•Phillips crossby’s Quality education system at Bharti Telecom.
•Internal Auditor training at ETDC, Mahali.
•Six Sigma at ACMA (DOE Tools).
•ISO/TS-16949, ISO-14001, OHSAS-18001 at Krishna Maruti Ltd.
•ISO-27001 (ISMS) at Polyplastics.
•Statistical process control at Hero Cycle, Ludhiana.
•SQCI, ROHS at SIEL and LG.
•National seminars on polymers at Chandigarh.
•Communication skill, Listening skill and presentation skill at BTL.

I  IMPARTED TRAINING TO MY SUB ORDINATES :-
•ISO/TS-16949, SPC, MSA, 5-S, Visual Management.
•TQM, TPM and TPS.
•General awareness training on ISO 14001/BS OHSAS 18001.
•Internal auditor training on ISO 14001/BS OHSAS 18001.
•SPC,7-Quality Tools, Quality Circle, PFD, FMEA and Control Plan.

Future Goals

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