Industrial Engineer
Sun Pharmaceuticals Ind. Ltd.
Total des années d'expérience :11 years, 9 Mois
Key Deliverable
•Solely responsible for IE studies and productivity improvements in SOLID & ORAL MANUFACTURING and Packing.
•Gone through VSM and identified present working methods, work layout, material handling and material movement procedure through various IE techniques like operation charts, bar charts, flow diagram, flow process charts, man machine chart and travel chart.
•Gone through method study, identified bottlenecks and NVA and optimized process in order to reduce cycle time.
•Gone through various work measurement techniques like time & motion studies in order to set productivity standards for each workstation.
•After gone through work measurement have set standard manning levels section, line & product wise by elimination of NVA and activities clubbing.
•Done significant working in context of capacity calculation from macro to minor level. Capacity calculation is done department wise, area wise, line wise & equipment wise based on different process parameters.
•Have set standard cycle times for all the products of granulation, compression, coating & packing section by keeping in account parallel working of man & machine elements and removal of non value added activities.
•Have set standard cycle times product wise in totality from manufacturing to dispatch, continuous monitoring of actual total cycle time product wise and publish difference of cycle times to management.
•Apart from capacity calculation on the basis of different process parameters have done capacity calculations on the basis of routing (on the basis of budgeted product & yearly volumes of products).
•Gone through capacity calculation and work measurement, have set productivity standards in terms of tablet/day, Manning/day and substantially tablets/man-day.
•Gone through detailed study of changeovers which happen product to product and applied various concepts of IE techniques like SMED, bar charts etc. In order reduce changeover time and cycle time.
•After setting standards have gone through continuous monitoring of actual productivity on weekly and monthly basis.
•Gone through data collection in all the section in order to identify reasons of gap between standard and actual productivity and intensity of each reason % wise.
•Continuously coordination with all the department heads in order to take trials on manpower rationalization, to let them know the difference between actual and standard productivity, reasons of downtime & their intensity and idea generation and implementation in order to eliminate/reduce controllable downtime to meet standard productivity.
•Have set OEE format for all the section and successfully monitored OEE on monthly basis.
•Gone through continuous monitoring of productivity trends of various department, all over plant, contract worker, permanent worker & staff.
•Gone through person wise productivity monitoring in order to set performance measurement of line officers and make them responsible by publishing their productivity figures.
•Given various automation proposals and implemented successfully in packing department.
•Given various proposals of validation of products on machines in such a way that WIP remains minimum.
•Have gone through manpower planning on the basis of RFC.
•Apart from Halol plant I have worked at Sun Parma’s Sikkim plant also for duration of 1 month in Warehouse, Manufacturing and Packing sections.
Key Achievements
•After gone through IE studies, manpower rationalization after taking product wise on floor trials with department heads, cycle time reduction, Changeover time reduction and successfully implementation of various automation proposals eventually we were achieve significant amount of results which are listed below.
•Manpower rationalization in Warehouse, Manufacturing and Packing section by 18.9 %, 20 % and 15.5 % respectively.
•Productivity improvement in terms of tablets/man-day in Warehouse, Manufacturing & Packing section by 23.3 %, 25.1 %, 18.3 % respectively.
Have successfully done my bachelor of engineering in industrial engineering specialization with distinction and without any ATKT. Industrial engineering is a branch of engineering dealing with the optimization of complex processes or systems. It is concerned with the development, improvement, implementation and evaluation of integrated systems of people, money, knowledge, information, equipment, energy, materials, analysis and synthesis, as well as the mathematical, physical and social sciences together with the principles and methods of engineering design to specify, predict, and evaluate the results to be obtained from such systems or processes. Its underlying concepts overlap considerably with certain business-oriented disciplines such as operations management. The various topics concerning industrial engineers include management science, work-study, financial engineering, engineering management, supply chain management, process engineering, operations research, systems engineering, ergonomics / safety engineering, cost and value engineering, quality engineering, facilities planning, and the engineering design process. Traditionally, a major aspect of industrial engineering was planning the layouts of factories and designing assembly lines and other manufacturing paradigms. And now, in so-called lean manufacturing systems, industrial engineers work to eliminate wastes of time, money, materials, energy, and other resources.