BRAKES INDIA LIMITED
Total years of experience :22 years, 9 Months
From August 1992 BRAKES INDIA LIMITED Chennai, Tamil Nadu, India
DEPUTY MANAGER - MANUFACTURING AND SYSTEM ENGINEERING AND NEW PRODUCTS (2010 - till date) reporting to General Manager - Operations, liaising with Functional Heads & mentoring 7 Functional Leads.
Key Result Areas: Containing cost of 'S' Cam Brakes, Master Cylinder and Wheel Cylinder; Hand-holding preproduction launch of New products; Leading Engineering Changes on current & forward models; Developing Value Addition & Value Engineering initiatives for current & forward model products & processes; Formulating new ERP / IT systems & supporting launch of autonomous facilities; Mentoring Functional lead engineers to achieve their official & personal goals.
Coups
• Capacity addition and projection investments to achieve business plan
• Championed Engineering Changes & implemented localized components including Rollers and Fulrum pins, Adjuster shafts, Cables for parking brake, resulting in Lead time reduction of 5 days & annual cost saving of 1.1 m USD.
• Outsourced & established complete vendor system for wheel cylinder machining thereby de-bottlenecking assembly operations, improving OEE by 6%
• Lead as Program manager for Light commercial vehicle back plate assy transfer business
• Lead PFMEA reviews for the new programs
• Coordinated with Testing function to validate the Auto adjuster Brake Assy.
• Lead Management reviews of new projects highlighting critical path, Project Cost, Quality & mitigated the risk.
• Championed perfect launch Auto adjuster LCV assembly.
• Implemented Kanban, Super market & Visual factory concept as part of Lean Manufacturing Systems resulting in four manpower savings per day.
• Motivated reporting function lead engineers to work smart & mentored them to achieve their official & personal performance goals.
ASST. MANAGER - MANUFACTURING AND SYSTEM ENGINEERING AND NEW PRODUCTS ( 2005 - 2010) reporting to General Manger - Operations & mentoring 4 line engineers
Key Result Areas: Driving Productivity, Quality, Delivery, Safety objectives of Starter motor & kits; Containing Manufacturing cost of Wheel Cylinder and Master Cylinder; Manufacturing lead for safe launch of New products; Mentoring engineers to achieve their official & personal goals.
Coups
• Served as Systems lead for TS 16949 recertification by BVCI. Introduced Poke-yokes for all Fit Form Function thereby reducing RPN rating by 15 % as part of FMEA reviews.
• Developed a bush and oil seal press with complete product poka-yoke and safety poka-yoke i.e, with load sensor to check both both bush and camshaft bracket over size and under size and also oil seal presence. To check the reverse oil seal assembly introduced the concept of air catch sensor and the locator was designed to detect the low back pressure.
• Championed corrective action and investigation report for various Customer Complaints including warranty rejects & implemented Robust corrective actions which include various detective & preventive poke-yoke.
• Served as Secretary of Safety council assisting an immense target "0 accident for 500 days" to come true. Being part of OHSAS review team, implemented countermeasures for near miss accidents.
• Championed perfect launch (Productionization) of Chamber bracket cell for Volvo.
• Motivated reporting engineers & mentored them to achieve their official & personal performance targets.
SENIOR ENGINEER reporting to General Manger application engineering ( 2000-2005)
Key Result Areas: Ongoing Product Development of Wheel Cylinder and Master cylinder, 'S' Cam brake and Hydraulic drum brake; Developing test procedures, sequences for current & forward model validation; Line/Field return reject analysis; Resident Customer support for Ford, Volvo & Jaguar.
Coups
• Coordinated and introduced New Products for TML and Mahindra & Mahindra.
• S Cam brakes for our clientele Tata, Ashok Leyland manufacturing light and heavy commercial vehicles
• Hydraulic drum brakes of our client TML, M & M manufacturing multi utility vehicles
• Implemented design modifications to indigenise honing tools and tool holders
• Worked with Volvo/Ford in analyzing & implementing corrective actions for Brake Assy.
• Worked with Ford team in analyzing & implementing corrective actions for Master Cylinder recuperation issue.
• Reviewed, corrected slack adjuster blue prints with respect to application perspective with Customer.
• Championed warranty analysis of wheel cylinders. Devised Quality Improvement Plan for continual improvement of the products & system together with Research Vehicle Team & Product Vehicle Team.
ENGINEER reporting to Manger - MSE & New products ( 1992 - 2000)
Key Result Areas: Implementation of Manufacturing excellence initiatives.
Coups
MANUFACTURING SYSTEMS ENGINEER Manufacturing systems Engineering implementation on 'S' Cam Brake manufacture at Brake Unit, resulting in lean production & 8 manpower savings.
• Introduced of mistake proof features & semi-automations like Air torque tools, handy coders & auto greasers & eliminated operator fatigue on critical areas.
• Improved operator / line efficiency by 30% through line balancing of assembly cells.
• FMEA review member - revisited 12 family groups. Department Coordinator - QS 9000, Continuous Improvement Team member.
• Relayed layout of AL shoe line with Line balancing - 2 man power savings, Space productivity increase by 30%,
• Introduced new process Rolling replacing Forming saving by 20 HP, & increasing space productivity by 50 %
• Reviewed process flow design / layout & coordinated in development of packing / kitting SPM's.
• Zero defect member - Eliminated 3 A type & 2 B ( Chronic) type defects in MIG welding process, Eliminated 2 A type defects in Lining riveting.
• Kobetsu Kaizen subcommittee member - Increased Overall plant efficiency from 64 % to 83 % Implemented SMED in 6 machines.
• Implemented Visual factory - Made pallet-less dream shop come true.
