dinesh chalamalasetti

Injection molds (0.4T-22T) | Hot runner systems | High-speed stamping dies
• Conduct Root Cause Analysis (RCA) on mold failures to minimise repeat breakdowns and production loss
• Perform preventive & predictive maintenance (PM/PdM) improving overall equipment uptime
• Monitor MTBF & MTTR metrics to enhance equipment reliability and reduce unplanned downtime
• Lead a team of technicians and manage spare parts planning for optimal inventory control
• Maintain hot runner systems, slider & core mechanisms, venting & polishing across 0.4T-22T molds

Tool room operations | ISO/IATF documentation | Process optimisation
• Reduced downtime by 25% through implementation of a structured preventive maintenance system
• Supervised tool room operations and ensured full compliance with ISO and IATF documentation standards
• Improved workflow through systematic process optimisation and team coordination
• Maintained zero safety incidents throughout tenure

MTBF improvement | Lean manufacturing | Kaizen | Cost reduction
• Improved MTBF by 20% and reduced MTTR by 30% through structured maintenance protocols
• Reduced tooling cost by 18% through repair and reuse initiatives instead of part replacement
• Implemented Kaizen, 5S, and lean manufacturing improvements across the tool room
• Coordinated with production team to minimise tool changeover time and optimise scheduling

Stamping dies 300-400 SPM | Injection molds | Precision machining ±0.05mm
• Worked extensively on high-speed stamping dies (300-400 SPM) and injection molds in a Japanese
manufacturing environment
• Achieved 12% cycle time reduction through tooling optimisation and process improvement
• Performed precision machining maintaining ±0.05mm tolerance for critical tooling components
• Gained hands-on experience in EDM electrode handling, tool alignment, spotting & tryout