Senior Production Manager
Genrobotics Innovations Pvt.
Total years of experience :27 years, 7 Months
Responsible for the Man, Machine, Materials & Methods of Production, Purchase, Administration and Maintenance activities of overall operations of Three Production Plants.
Planning and organizing the manufacture of Automated Manhole Scavenging Robotic machine-BANDICOOT, MOBILITY PLUS, Gait training Robotic platform G-GAITER, WILL BOAR, GEN BOT and ROV.
Manage the overall Fabrication activities includes Sheet metal bending, Structural fabrication, Hemming, Pipe bending, ARC, TIG, MIG welding in MS, SS & Aluminum materials.
Providing Technical know-how to the team for hydraulic, pneumatic, electrical & electronic assembly works in various Robotic Products.
Monitor & control the workflow in subdivisions-Fabrication, Assembly, and Testing while optimizing the process, meet delivery, minimize the wastage of material, manpower & machine time.
Participating the manufacturing activities of all plants related to productivity, quality, cost control, innovation, OHS, inventory and supply chain management.
Oversaw the generation of maximum profitability with full production levels, identifying & rectifying the areas of quality failure and ensure smooth day to-day operations.
Determining KPI of the team members and measuring them regularly.
Developing & monitoring the preventive maintenance program for the Equipment, Tools & Plant,
Recruit, hire, train (OJT), develop and evaluate the production workers.
ACHIEVEMENTS:
Career growth to Senior Manager within three years from Managerial level.
Design & developed new compact components for the Robots to maximizing the product durability.
Implemented the QMS and obtained ISO 13485 for Gaiter - Medical Product.
Managed a team of 60 plus members including Managers, Supervisors & multi-disciplined workers in three plants for efficient performances.
Initiate, manage the diagnose, trouble shoot of KUBOTA Mini Excavators, CASE Backhoe Loaders, Road Rollers, Soil Compactors, NEW HOLLAND Tractors, HYVA Tippers and Cranes.
Responsible for the of repair, service and overhauling of Diesel engines, Torque Converters, Clutches, Transmission Gear Boxes, Differentials, Axles, Drive shafts, Steering, Brake systems, Hydraulic cylinders, Motors, Winches and Control valves.
Reviewing the OEM service manuals and implemented the OEM service procedures.
Providing the value engineering, technical know-how to the onsite service team for enhancing the preventive, breakdown maintenance, and repair of Equipments.
Diagnose the failure, prepare estimate, Convince & negotiation with customer, Acquisition of orders, Organizing and executing the repair works within the deadlines.
Extensive involvements with the customer in all phases of remedial works and obtained the high-level customer satisfaction.
Leading & Supervision of multi-disciplined team for efficient performances, maximize the quality and quantity of production, identifying the areas of quality failure and take steps to rectify them.
ACHIEVEMENTS:
Streamlined the Service operations in Southern Province of Kerala for four Brands and expanded the customer base.
Handled the four different Dealership Product lines efficiently and enhanced onsite service revenues.
Responsible for the Repair, Maintenance, Service, Production works associated to Hydraulic machines / Equipment / components such as cylinders, pumps, motors, valves, accumulators and power packs.
Repaired various Heavy lift, Material handling, Bulk transport, Construction and Waste Management Equipment.
Diagnose, Preparing Estimate, Quoting & Convincing the customer, Acquisition of orders, Organizing and execution.
Manage, coordination, provided technical guidance to the workshop team and ensured zero defects.
Direct supervision of Hyd. Repair/Production, Metal Fabrication, Machine shop, Assembly and Testing divisions.
ACHIEVEMENTS:
Reduced rejection rate of repair and production works by effective team monitoring & innovative technical solutions.
Increased the Workshop sales revenue above 25 % by the Quality of Services and customer retainability.
Manage the overall workshop activities includes Sales, Services, Repair, Production works associated to Hydraulic machines / Equipment / components such as cylinders, pumps, motors, valves, accumulators and power packs.
Diagnose, identify the failure cause, preparing estimation, convince with the customer, acquisition of orders.
Planning, scheduling, execution and completion of order within the deadline.
Direct supervision, coordination of technical team and provided technical guidance in Production, Repair and Machine shop services.
Repaired the Hydraulic pumps REXROTH, SAUER DANFOSS, VICKERS, PARKER, EATON, KAWASAKI, DENISON, LINDE & STAFFA.
Identify and select the required resources for the company such as, manpower, materials, machines & tools.
Prepare Techno commercial offers for Hydraulic Equipment, Cylinders, Pumps, Valves and HPU.
Liaising with suppliers to establish long term relationships and maintain stocks for overall business.
Monitoring and controlling of Machine Shop, Fabrication, Production /Repair jobs by effective technical solutions.
ACHIEVEMENTS:
Streamlined the new company operations and Increased turnover along the customer base above 50%.
Made operation of Hydraulic Pump & Cylinder Test Benches.
Responsible for the establishment of new branch into operation by handling all positions.
Manage & lead the departments such as Counter sales, Seal, Factory, Stores, Purchase & Accounts and maneuvering for its cost effectiveness and higher productivity.
Organize & allocate all the functions of departments, provide on the job training,
Direct Supervision and Control of branch team for their efficient performances.
Give day to day technical support & guidance to the Factory team in manufacture of hydraulic parts, diagnostics, repair of hydraulic, pneumatic cylinders, pumps, motors, winches, valves, power packs, machineries, Sky lifts, Material Handling & Heavy Lift equipment.
Design, manufacture of new hydraulic power units, cylinders and monitor the production process in all stages for high durable products.
Extensive involvements with managing the customer relationship at all levels and earned high level client satisfaction.
Identify, Select & update the required resources for branch such as, manpower, materials, machineries & tools.
ACHIEVEMENTS:
Streamlined the new branch operations within the available resources and made into profitable center.
Increased turnover up to 50% by improving the Quality of Service and expanded the customers base by 50%.
Initiate, manage the diagnostics, trouble shoot of KATO, XCMG Truck Cranes, Rough Terrain Cranes, KOMATSU Wheel Loaders, Dozers, Graders, Excavators, Forklifts, Backhoe Loaders, BOMAG Road Rollers, KUBOTA Tractors and SULLAIR compressors.
Responsible for the of repair, service and overhauling of diesel engines (FIP, CRI & HPI Type), Torque Converters, Clutches, Transmission Gear Boxes, Differentials, Axles, Drive shafts, Steering, Brake systems, Hydraulic cylinders, Motors, Winches and Control valves.
Reviewing the OEM service manuals and implemented the OEM service procedures.
Providing the value engineering, technical know-how to the workshop team for enhancing the preventive, breakdown maintenance tasks.
Extensive involvements with the customer in all phases of remedial works and obtained the high-level customer satisfaction with enhanced sales growth.
Leading & Supervision of multi-disciplined team for efficient performances, maximize the quality and quantity of services, identifying the areas of quality failure and take steps to rectify them.
Direct & monitor all the activities of Nizwa branch operations such as resources, sales, costing, quoting, purchasing, parts, and inventory.
ACHIEVEMENTS:
Streamlined NIZWA branch operations, increased the revenue and made into profitable branch.
Executed various repair and services of Cranes at PDO area by deploying satellite teams.
Repaired various Construction, Material & Agriculture Equipment by prompt on site services.
Handled the critical product / service issues and taken critical warranty decisions amicably.
Responsible for overall management of workshop activities from conception to the completion of administrative, resources, Walk-In sales, costing, quoting, planning, purchasing, scheduling and execution of hydraulic engineering production, services, trouble shooting, overhauling and repair tasks.
Responsible for the problem identifying and troubleshooting of industrial hydraulic, pneumatic cylinders, pumps, motors, valves, accumulators, power packs, press machines, and Heavy Lift equipment (Rough Terrain Cranes, Truck cranes, Tippers, Skip & Hook loaders, Refuse compactors, Lift & Tail gates, Vibro & Hydro Hammers, Vacuum pumps, Dewatering & Jetting pumps, Concrete pumps & Mixers, Air Compressors, Blowers, Diesel engines, Bulk &Fuel tankers).
Re-engineering and performing the new equipment installation, commission of HYVA, HMF, KENNIS, ERHEL HYDRIS, DHOLLANDIA, ULTRON, LINCOLN, MORO, JUROP, BATTIONI, ALUP, VM MOTORI, EUROPA, BLACKMER and GARDNER DENVER.
Designed and manufactured the new Hydraulic Power Packs for industrial applications with parts from EATON,
PARKER, REXROTH, CASAPPA, OIL CONTROL, SUN, HYDRO CONTROL, VOSS, CONTARINI, EMMEGI, SIMRIT, ERIKS, HALLITE, MPFILTRI, INTERNORMEN and AEROQUIP.
Preparing hydraulic schematics, selecting hydraulic parts for various application in Industrial & Mobile hydraulics.
Direct supervision of Machine shop (Lathe, Milling, Radial drilling, Boring, Grinding & Polishing), Weld Shop (ARC, MIG & Gas), Fabrication shop (Skid & Oil Tanks), Repair shop, Assembly, Testing and Paint shop.
Reviewing the direct & indirect material consumption and optimized the production / Repair cost to the company.
Organize day-to-day workshop activities related to resources requirements, production, repair, service quality. problems and Implemented QMS of ISO 9001 in the Production, Repair and On-site services.
Liaison with supervisory staff, monitor, control and direction of mufti-disciplinary, multinational workforces to improve their job performances.
Extensive involvements with managing of customer relationship at all levels, Increased loyalty of customers by providing prompt services following TQM & obtained high level customer satisfactions through high durable services.
ACHIEVEMENTS:
Career growth to Managerial level within four years from Supervisor level.
Increased the workshop repair sales revenue from SR 100K to 600K monthly.
Managed the major ten divisional tasks at different stages for cylinder, pump, valve, mobile, machine shop, hose, fabrication, welding, on-site services and electrical sections.
Provided valuable training (OJT) to 30+ workers in technical issues and troubleshooting of Hyd. Machine/Equipment.
Re-engineered and implemented effective sealing solutions to Hyd./Pneu. actuators & control valves without OEM kit.
Handled the critical product / service issues and taken critical warranty decisions amicably.
Repaired 300 Ton Lattice Boom Crane’s Hydraulic Backstop Cylinder with Hydro-Nitrogen.
Executed Jeddah Port Container Scanning HPU unit project and Hydraulic Material Lift in Patchi Jeddah Factory.
Responsible for the Planning, Preparation of Project charts, Arrangement of resources required for Installation & Commissioning of MöLLERS Automatic Palletizing & Wrapping production line for SHARQ (A SABIC Affiliate).
Co-ordination with supplier and the client for implementing Quality Objectives of projects and reported with Progress Computation & Installation Charts.
Organizing, allocating of day-to-day tasks to the multi-disciplined team and supervise the progress of work in all stages of project.
One year manpower contracted to, Dec’ 1997 - Jan’ 1999 SAUDI IRON & STEEL CO. (HADEED)-(A SABIC affiliate) Al- Jubail, Al-Sinaiyah-31961, K.S.A.
Liaison with HADEED maintenance department to carryout Preventive Maintenance on Capital/Non-Capital Plant spares such as Hydraulic cylinder, Power pack, Gearboxes, Pumps, Compressors, Fans/Blowers, Bearing Housings, Couplings, Drive shafts, Piping, Process vessels, Conveyor systems, Electrical Motors and Transformers.
Responsible for the Planning & Organization of daily preventive maintenance tasks to the multi-disciplinary, multinational team of ten members.
Direct Supervision & Control of the team for efficient performance and Report to the client HADEED on plant spares preventive maintenance tasks.
Routine Inspection on the condition of plant spares and organizes the necessary preventive maintenance tasks.
Co-ordination with operational engineers for the associate maintenance activities on all types of plant spares and implemented the Environmental Protection techniques against spares deterioration, and availability.
ACHIEVEMENTS:
Successfully Completed the project management task i-e Stock Preventive Maintenance Dept. in HADEED.
Handled the MöLLERS Automatic palletizing & Wrapping line installation & commission at SHARAQ.
Designing, Drawing, preparation of BOM of hydraulic cylinder and preparation of drawings of single & double acting, screwed & spring-operated types.
Interacted with other dept. on regular basis and performed the inspection, testing of product at various stages.
Review the product complaints and implement remedial /design development process.
ACHIEVEMENTS:
Accomplished the pneumatic chute cylinder design for Vijayawada Thermal Power Station.
Provided new product training to the Tanjore Municipality team for commissioning of Aerial Work Platform.
Responsible for the Preventive & Breakdown maintenance, repair of mass Production tools, dies, jigs & fixtures for the Broaching, Boring, Injection Molding, Dynamic Balancing, Drilling, Marking, Riveting, Embossing, Assembling and Testing machines.
Performed trouble shoot by implementing the Root Cause Failure Analysis (RCFA).
Provided effective technical solutions in Production Engineering Dept. activities and reduced repeated failure.
Attend the call outs to rectify the breakdown with least machine downtime.
Interacted with tools supplier and maintained stock of tools for mass production line with maximum availability.
ACHIEVEMENTS:
Cut down repair cost of Tools, dies, Jigs & Fixture by imparted the design development,
Reduced the downtime in Tools, dies, Jigs & Fixture by performing effective Preventive Maintenance duties. Reduced the breakdowns by routine inspection, condition monitoring and adopting design improvements.