plastemartjobs.com Email: jobs@plastemart.com, hr@plastemart.com Download Date: 5/11/2025 5:29:09 AM ________________________________________________________________________________________ RefNo: CA - 17213 Gender: Male Age: 43 Designation: Senior Engineer Highest Education Level: Masters - Degree Education Details: M.B.A Operations Management From IGNOU, New Delhi in 2008 to 2010 With 66% Post Graduate Diploma in Plastics Processing & Testing ?From?CIPET Mysore in 2002 to 2004 With 76% B.Sc. in Polymer Chemistry From FMNC, Kollam, Kerala University in 1999 to 2002 With 75% ? Skill Sets: Operating System : Windows 7, MS Office 2010 Design Software : Auto CAD 2013 Work Experience: 19.3 Work Experience Details: Senior Engineer? Since Jan 2012 ? Company Profile: Leading manufacturer of plastic automotive products.?Is engaged in manufacture of injection molded automotive plastics parts for Interior, Exterior, Safety and Functional applications such as Instrument Panel parts, Front/Rear Bumpers, Wheel Caps, Weather Strips, Steering wheel, Radiator Grilles etc.? Job Profile: Heading TPS team to setup plant layout for new projects from incoming raw material to finished goods. Make MIFC-Material & Information Flow Chart for running and new projects to identify the bottlenecks and find solutions to improve the system. To develop Karakuri concepts to promote automation with innovative Kaizens for automotive assembly line. Makunouchi, Set-supply concepts for automotive assembly line. Achieve 20 mins internal parts pulling cycle with only 20 mins lean inventory. Establish levelled production by implementing HEIJUNKA post for Kanban system.? Design lean inventory trolleys/conveyors to store parts without secondary bins. To develop creative ideas to improve part flow, lean inventory, Just In Time system. Achievements/Accomplishments: Implemented Renketsu system to inter connect the inventory for FIFO system. Established 1.5 mtr safe vision height standard for the entire plant inventory to see from one end of the plant to other end.? Developed Karakuri system for assembly SET SUPPLY Makunouchi system. Implemented Binbiki system with 1 hr delivery cycle for outsourced parts. Heijunka system for levelled production. Designed and implemented lean inventory cart for automobile Bumper parts and removed conventional fabricated trolleys to avoid forklift stack/unstack operations inside the plant. Assembly Line?Engineer :?Jan 2009 to Jan 2012 Job Profile: Manage overall assembly line consisting of TOYOTA Innova, Fortuner, Corolla Altis, Etios, Etios Liva, Renault Nissan. Product Line Consisting exterior:- Cowl Ventilator, Grille Radiator, Hood Front, Garnish Back Door, Weather Strips etc. Interior:- Instrument Panel Parts - Center/Meter Cluster, Door Glove, Console Box, Cigar Lighter, Ash Tray, Engine Cover etc. Responsible for production planning, capacity planning, manpower planning, resource planning, training, multi skill development, inventory control, built in quality, control of direct consumables to production line. Productivity improvement through time and motion study, cyclic operation, cycle time reduction, Kaizens. Elimination of non-value added activities, defect outflow prevention, system improvement. Core responsibility for new project trial runs, high volume production runs, standardisation. Achievements/Accomplishments Space productivity by setting up MINOMI concept in production-assembly. Implemented LUNCH BOX system for entire assembly line to prevent defect outflow & to follow right assembly sequence. Best KAIZEN award for cycle time reduction, elimination of MUDA part/man movement for INNOVA assembly line. Project Management Personnel:?Jan 2007 to Jan 2009 Job Profile: Customer project enquiry review, drawing review, product information, determine project realization requirements. Interpret drawings, technical instructions, summarize list of parts, tools, raw materials, child parts, special process, tools & equipment, vendors etc. Preparation of project milestone management, setting up MDT, APQP plan. Draft out process design, process flow, process layout and master part list. Conduct MDT meeting and timely review of visual controls to update the project status. Product quality system review, quality assurance schedule, part evaluation plan. Project Kanban system- routing, Kanbans in circulation.? New vendor development ? raw material, child part, special process etc.? Core responsibility for planning & timely execution of stage wise trials In-house and at supplier end. Review of mass production preparedness, coordinate high volume trials and evaluate efficiency and effectiveness of development process.? Cost reduction, value addition and value engineering.? Achievements/Accomplishments: Successful management of projects: TOYOTA INNOVA, Corolla Altis, Fortuner, Etios Seddan, Hatch Back, Renault Nissan. Track record of timely delivery of off tool ? off process parts and for successive events till mass production. Localization of raw material for non aesthetic parts in compliance with TOYOTA standards.? Cost reduction by developing paint base coat for parts with two color variants for cubic printing. Localization of imported child parts like cushions, non-woven fabric, seals, adhesive tapes etc. in compliance with TOYOTA standards. ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? Quality Management :?Jan 2005 to Jan 2007 Job profile: In-house quality control at various stages; receiving inspection, production line, assembly, dispatch. In-house standardization of production process & stabilization. Preparation of PPAP documents like process flow, PFMEA, Control Plan, Inspection Standards, Boundary Sample, One Point QC etc. Process Capability studies Cp, Cpk, Measurement System Analysis [MSA]. Measurement of product, end product use with respect to fit, form & functional requirements. Monitoring and measuring customer satisfaction, supplier performance. Responsible to achieve customer PPM targets. Cost reduction activities through KAIZENS. Root cause analysis and countermeasure through 4M, PDCA, 7 QC tools etc. Raw material evaluation and testing, product assembly and testing. Certified internal auditor for ISO/TS 16949 Quality Management Systems Achievements/Accomplishments: Solved clearance problem in Door Glove Outer/Inner assembly by developing air cooling jigs, to place molded part right after production to retain the shape. Eliminated problem of extra plating deposits at edges of Hood Front by proposing design change, provided additional plating rib/robber to catch extra deposits, which is removed after plating. Suggested tool corrections in different parts to achieve complete noise reduction by eliminating problems like gap/clearance, rattling sound etc. Appreciation from Top Management for achieving customer PPM target consistently. Active participation in Quality Circles? Excellent award for Quality Circle Competition from Customer Production In-Charge ? Feb 2004 to Jan 2005 Company Name: Big Bags International Pvt Ltd Company profile: An ISO-9001-2000 organization, largest manufacturer and exporter of Flexible Intermediate Bulk Containers (FIBC), Container Liners and Tarpaulins. Machinery: Sheet Extrusion plant (260Kg/hr, 160Kg/hr) producing PolyPropylene Tapes, Blown Film Plant (100Kg/hr) producing Poly Ethylene tapes, Extruder for laminating woven fabrics (both tarpaulin & FIBC). Job profile: Production planning & control for the extruder departments. Prepare daily production, material status reports, overall production status. Making presentation in the daily review meeting with the management. Assigning monthly & daily production targets. Project: Jit ?A Means For Productivity Enhancement Project report submitted to IGNOU in partial fulfillment of the requirements for the award of the degree of Master Of Business Administration The project highlights that the JIT philosophy has the potential for increasing organization efficiency and effectiveness. It makes the organization to modify its operating procedures, production system, the plant layouts have to be changed, relations with suppliers, kaizens and work culture. It enables the firm to reduce inventory carrying cost, reduce lead time, decrease throughput time, improves production quality, increase productivity and enhance customer responsiveness. The project has shed light on KANBAN circulation in the system and also the contribution of various factors in determining the number of Kanbans required in the system. Certificate Programs: Management Assistance Program on Plastic Industries. Advance Techniques in Tooling for Plastics. Future Goals: To contribute my potentials for the entire satisfaction of the concern I work for and to grow along with it. To achieve rich experience in Technical and Management areas. ________________________________________________________________________________________