Executive, Operations Engineering
Guardian Industries
مجموع سنوات الخبرة :9 years, 5 أشهر
Executive, Operations (Project Engineering, Process Design & Production) 3/2017 to 11/2020
Utilizing the experience of previous Automobile industry and taking the company through the journey of establishment of ISO9001:2015 and ISO 14900:2018 successfully with continual surveillance till 2020.
Immersion with a goal to develop Virtues for enabling creation of value for the customer, society and environment via MBM® Philosophy - Guiding Principles and Role of a Supervisor Framework in order to achieve the Department Shared Vision.
Resolving Top Customer Complaints (CAPA/CAR) utilizing 8D Analysis Model and bringing a significant reduction in the Claims Settlement. (Utilizing Master Control® for a Systematic Approach)
Working in the capacity of a Production Executive, managing a team of 21(ITI/Diploma Holders) for the production, processing and packaging of Glass as per customer requirement.
Improvement in Production Process through Continuous Improvement and Removal of Non-value-added activities/Waste Reduction. (Lead Winning Team in State Level CII Kaizen Competition 2018 and Runners Up in Regional Level CII Kaizen Competition 2019).
Feasibility Study for New Products (Proto PFD, FMEA and Control Plan) to prepare the Operational Budget and CAPEX for New Facility and Tooling
Scheduling Production Run on a 48-hour basis, Optimizing Manpower Management, Talent Development and improvement of Skill Score, Upholding the standards of ISO 9001 and IS 14900 on a shift-to-shift basis.
Senior Engineer, Production Engineering, New Product Development 4/2015 to 2/2017
Implement and refine manufacturing processes by applying continuous improvement and lean manufacturing principles to automobile Heat exchanger area, rail ac and home ac area. (Carry out PFMEA and Control Plan Review Meetings with CFT at regular frequency)
Designed and Developed the Machining processes, aluminum brazing and welding procedures for the manufacturing of Heat Exchangers for commercial vehicles through a Continuous Aluminum Brazing, CAB furnace.
Reconfigured dispatch layout and improved the packaging solutions for rail ac and bus ac, which improved worker efficiency, reduced dispatch time by 50% and dispatch cost by 36% per kit.
Upheld quality standards (PPAP) and multiple air-conditioning kit manufacturing project portfolios that helped the operations team earn export business for major OEM’s namely Renault Nissan, Daimler, TATA Motors, Mahindra and Mahindra, MREVA, Maruti Suzuki and Force Motors.
Preparation of Machine Specification sheet and carry out the Commissioning before Handover to Production with Spare Estimation, Calibration Requirements and Process Trials. Implementation of new and efficient process technology like RAIN Testing for AC Kits, Exploring Portable Hand Tools for assembly operations, material handling equipment for safe practices and overall lower cycle time (Reducing Bottle-Neck)
Senior Engineer, Industrial (Process and Methods) Engineering 4/2015 to 2/2017
Line balancing by elemental breakdown, cycle time study, GANTT Chart Analysis and SMED for the optimization of Process and reduction in manufacturing cost and enabling Heijunka.
Preparation of Capacity enhancement requirements through the Annual Operating Plan (AOP) along with Project implementation Benchmarking, Scheduling and Budgeting / Facility Cost Estimation.
Low Cost Automations (Kaizen) for improvement in Production and Manufacturing equipment.
Production Validation of process for current capacity estimation and optimization utilizing Value Stream Mapping tools. SPC and AutoCAD.
Routing of Manufacturing Process in SAP for estimation of process cost through variables like manpower utilization, utilities and resources.(CA01, 02, 03)
Manpower estimation for the Complete Plant to post the requirement to HR for Contractual Requirement on basis of Cycle Time Study and Line Balancing.
OEE estimation, monitoring and analysis, Removal of Wastes (MUDA), implementation of KANBAN System and TPM Philosophy for efficient material flow, ensuring product CTQ parameters and machine upkeep.
Increasing productivity through combined work steps, removing non-value added tasks, adding automation and the development of effective work practices
Engineer, Facility Establishment and New Product Development 8/2012 to 3/2015
Provided engineering solutions for new product introductions, handling all phases of manufacturing from concept through to production launch. (Including PPAP Process Documentation)
Managed process benchmarking, prototype build, design for manufacturability and assembly (DFM/DFA), vendor process engineering and tool development (sheet metal, rubber, tubes and off-shelf products), In-house value stream mapping, production trails, process performance study, FMEA and development of requisite tooling and gauges (JFT), defining of production controls and Mass production trials at 90-95% line efficiency.
Served as a member of the Manufacturing Engineer Group accountable for developing cost-effective solutions to manufacturing production issues through QC and CFT Approach. (Handled a team of 5 Diploma Holders)
Support to company management by being a window person for the liaison to procure government approval by editing and iterating CAD Layout and preparation of SLD & BOQ for in plant provisions and establishment of Pre-Engineering Building Site of 10 Acres including installation and commissioning of site offices, test labs, utility piping, compressed air, RO-DM Plants and 1200 kVA Electrical Infrastructure for brazing furnace and multiple manufacturing and assembly lines.
Preparing detailed machine specification write-ups for procuring machinery for R&D Validation labs, Quality reliability and durability studies, manufacturing and inspection SPM’s. Moreover, enabling the handover process by organizing safety, operation and maintenance training for the operators.
Upheld quality standards that helped the Operations Team to earn ISO/TS 16949:2007 accreditation for the Greenfield Project.
Graduate Engineer Trainee, 7/2011 to 7/2012
The Training methodology is a global benchmark from the World Leader in Automobile HVAC Denso Limited which included meticulous rounds of dynamic job rotations in multiple departments, primarily Operations, Quality and Maintenance and intense classroom training sessions, covering core tools and concepts APQP & DFMEA, FMEA/Control Plan, PPAP, SPC, MSA.
Projects presented during the GET Period:
• Study of air flow analysis of HVAC Units with vehicle ducts in a Production Line as ELI (End of Line Inspection) utilizing the principle of Balometer.
• Design, Developed and Commissioned a NI PLC based electrical test bench for the purpose of inspecting the performance of Servo Motors in HVAC Units controlling the mode selection cooling damper and heater damper, utilizing Lab View as the programming language for logic control. This project was responsible for TATA signing off on the PSW for the SAFARI Storme Project.
• Line balancing utilizing the Lean Management principles on production lines enabling Manpower Optimization and reallocation of resources for Value Added Activities.
B.Tech in Mechanical Engineering, 2:1, 5/2011, CGPA 6.23 National Institute of Technology, Himachal Pradesh, India Modules Included: Mechanics of Solids, Fluid Mechanics, Manufacturing Processes, Machine Drawing and Solid Modelling, Thermal Engineering, Automobile Engineering, Kinematics and Dynamics of Machines, CAM, Production and Operations Management, Mechanical Vibrations, Mechatronics, Industrial Engineering, Refrigeration and Air Conditioning. Electives: Finite Element Analysis, Nanotechnology, Digital Image Processing using MATLAB Dissertation: The performance of a Four Stroke Spark Ignition Engine using Hydrogen-Ethanol blends as a fuel has been studied. Acheivements: 1. Vocational training with the largest steel manufacturing plant in India, Bhilai Steel Plant. 2. Design of ATMEGA 128 Processor in Robotics Seminars and Industrial Training (RoboSapiens) to perform Simple Task (White Line follower and Beetle Bot)