Ref. No. : CA - 30856 - (Management – with 33.8 years in Plastic Industry)

Education

B.E. (Mechanical Engineering) PTD from Maharaja Sayajirao University, Vadodara. Gujarat
D.M.E. (Mechanical Engineering) from Maharaja Sayajirao University, Vadodara. Gujarat

Skill Sets

Core Competencies
Proactive and dynamic professional with a documented history of bridging technical and managerial acumen.
Handled various functions in manufacturing such as Production, Process, Quality, , Manufacturing Engineering,
Continuous Improvement, Material management, Sourcing, Procurement, Green field Projects Technical
Training, Planning & Packaging . Currently spearheading operations
Ltd., formally known as Visteon Technical & Service Centre – Lighting Division, Pune as General Manager
(Operations).
- Possessing valuable insights, keen analysis and team approach to implement best practices, adept at
working in high pressure environments with strict deadlines & multiple deliverables.
- Well versed with: - o Modern manufacturing tools such as World class manufacturing practices & systems.
Quality system knowledge of various OEMs (GM, VW, M&M, Tata Motors, VECV, etc.)
- Perfect Team Manager having ability to lead cross-functional teams and integrate their eff

Work Experience

General Manager (Operations)
From Feb’11 till date
Company profile- manufactures lighting systems. The Company offers advance front lighting, LED lamp, headlamps, and xenon lighting systems

Job profile-
Preparing, monitoring and controlling budget for Manufacturing, Procurement & project cash flow
requirement
Implemented world class manufacturing systems with visual control on shop floor.
Safety characteristic management by monitoring FTOVs (First Time Occupational Visit) to ensure zero
lost time case (LTC) in plant in last 4 years.
Monitoring the performance (PLP) of members to ensure efficiency in process operations and meeting of
individual & group targets.
Driving various improvement projects thus increasing the capacity of various sections of plant. This
allows accommodation new programs within existing resources.
Drive team for their active participation in DFMEA & PFMEA and control over Design & process changes.
Practicing “Layered Process Audit” involving all levels of employees in audit process.
Review of plant operational performance by daily monitoring of “Overall Equipment Efficiency” (APQ)
along with “output per man per shift” monitoring for assembly operations.
Instrumental in standardization of work & operator training through Dexterity school concept.
Imparting discipline on shop floor by exercising control over NC, Rework & Mix-up management and
error proofing (Pokayoke).
Constant watch & control over vendor rating by customer thus increasing probabilities of RFQs.
Fast response to customer concerns (official & non official both) using 8D approach. And applying the
same approach to internal concerns resolution.
Control on “cost of poor quality” by weekly review on effectiveness of action taken during internal
rejection & scrap analysis by team. Monthly review for warranty & premium freight.
Formulating plans for smooth execution of projects within time & cost parameters.
Lead role in new product launches & tooling development, supplier selection, price finalization & releasing
PO and liaising with vendors on continuous quality improvement by auditing them as per plan
Identifying and developing potential vendors locally & globally for achieving cost effective purchases of
raw materials and finished goods. • RMC control by effectuating cost saving initiatives by introducing advance product, process technology
and substituting process, use of alternate material.
Ensuring 100% delivery to customer for their OE and SPD requirements.
Overall supervision and administration in Stores from the receipt of material, storage of material,
issuance of material thought work order and their closer with data integrity

Significant Accomplishments: - Recognized for outstanding business communication skills, proven acumen in collaborating with the
key decision makers of the organization and achieving consistent success
- Made notable contributions towards attaining
Zero lost time case in last four years.
100% delivery adherence to customer requirement.
Scrap reduction from 8% to 4%
OEE improvement from 71% to 85% (Cycle time, breakdowns reduction & FTT improvement)
Layout improvement releasing 20,000 sq. Ft. of shop floor area for future business
Consumable cost reduction from 4% to 0.8%
25% Manpower reduction
Increase in output / man / shift from 30 to 47
Reduction in energy cost from 4.76% to 3.59%.
Reduction in customer complaints from 118 to 56.
- Distinction of serving 5 major four wheelers OEMs like GMI, VW, M&M, TATA Motors, Volvo Eicher & Fiat
(India). Gained sound knowledge of their individual quality system of various OEMs viz.:
VW - Quality Cockpit System
GMI - Quality System Board, 8D of Problem Solving
M&M - MSES and MMA – Only “B” grade supplier in India for the lamps.
- Experience in enhancing processes controls (Pokayoke) and reducing costs.

Assistant General Manager (Operations)
From NOV’09–Feb.’11
Company profile- leader in Platting and painting on plastics automotive parts like front grill, front and
rear garnish, exterior decorative parts, door handles emblems, etc. Largest wheel cap manufacturing facility
with automatic painting

NOV’06 – NOV’09 with Sumi Motherson Group as Manager (Maintenance)
Worked in three plants of Sumi-Motherson group – MATE Manesar, Noida and Pune. The core competency of
three plants lies in Injection Moulding, Blow Moulding, sub-assemblies & Paint Shop Major Customer Maruti
Suzuki, Honda Motors, VW, GM , TML and M&M .

Oct. ’98 – NOV’06 with Shaily Engineering Plastics Ltd. as Asst. Manager (Manufacturing)
Worked in different facility of Shaily Engineering Plastics Ltd. In Gujarat Halol and Rania, they are in
precession injection moulding components and post moulding operations like painting, assay, vacuum
metalizing, hard coat, etc. Major customers are GE, Emersion, Secure Meter, ABB, Alstom, Siemens, L&T, Ieaka,
etc.

JUNE’95 – OCT’98 with General Motors (India) Pvt. Ltd. Halol Gujarat as Area leader (Maintenance)

AUG’91 – JUNE’95 with Safari Industries (India) Pvt. Ltd. Halol, Gujarat as a Supervisor (Maintenance)
Worked as a Trainee Engineer to Shift supervisor, Safari Industries are in moulding and forming luggage

MAJOR AREAS OF RESPONSIBILITIES
Spearheaded Productivity Improvement Activities required for producing components while
controlling the cost and maintaining world class quality.
Propagated Quality Circle movement and developed quality culture in the work force to achieve
quality leadership in the industry.
Improved operational efficiency by enhancing capacity utilization, reducing rejections and nonvalue added activities and logistics improvement.
Assessed all staff to determine skill levels and core competencies; match competencies with
projects to achieve overall increased corporate engineering quality.
Organized various training sessions for the team to enhance their performance.
Structured annual operational budget and implementing control measures to contain expenses
within defined limits.
Developed SOP’s and ensured its implementation.
Key player in analysis, development, and implementation of strategic business plans & policies,
ensuring organizational growth, targeting maximum profitability & cost effectiveness.
Ensuring system compliance with respect to standard operating procedures and legal guidelines.
Implemented new inspection process, which identified and led to correction of potential defects.
Practiced predictive and preventive maintenance techniques to systematically address maintenance
problems and ensure maximum operational availability of machines.
Defined operational parameters and ensured strict adherence thereto to generate maximum
operational efficiency.
Successfully organized process quality control meetings for quality improvements.
Overall responsible for implementing effective systems, viz. Pokayoke, FMEA, JIT, TPM &
KAIZEN to reduce rejection levels and ensure conformance to pre-set quality standards.
Interfaced & coordinated for Machine selection for the new projects, installation, operation and
training, Utilities design, processes design, plant layout, etc.
Effectively liaisons with Government Authorities, viz. EB, PCB and Electrical inspector for
forthcoming Projects and development of existing plant.
Accountable for Chartered Engineer, Electrical installation approval by Electrical Inspector &
Electricity Duty Inspector
Formulated plan for implementing new process concepts for production optimization and
developed guidelines for the sequencing of manufacturing activities on the shop floor.
Led & guided the team in ensuring compliance to all Safety norms to minimize/achieve ZERO
accidents.
Streamlined Manufacturing System and implemented 5S Principles, Kaizen, & Quality Circles on
shop floor for continuous improvement - Lead a cross functional team of various departments.
Established plan for ensuring compliance to all HSE activities and practices.
Proactively contributed in assessing manpower requirements and conducting recruitment &
selection process using best sources of recruitment.
Drove initiatives to develop the SPM as per product requirement, Productivity/Process
improvement, Manpower reduction and also to develop the hydro pneumatic press, PLC operate
brass insertion machine for intake manifold, hot press insertion, duct cutting machine, profile
bending machine, etc.
Meticulously handled maintenance, programming of takeout robots & designing grippers (chucks).
Gained invaluable experience in operation and maintenance of Indian/Imported hydraulic &
mechanical plastics machinery with clamping tonnage ranging from 40 Tons to 3200 Ton of
various make like Krauss-Maffei, Engel, Batten field, Hwachin, Nissei, Fanuc, Nuchem,
Cincinnati Milacron, L&T, Demag, FCS, Borch, Mitsubishi, Toshiba and Windsor.
Associated closely in execution of new projects/plant setups, installation & upgradation of
existing machinery, machine utilization for maximum efficiency and energy saving with latest
technology including technical discussions with OEM and machine suppliers for improvements
in machine capability and performance.
Deftly managing electrical load calculation, electrical distribution system design in terms of
capacity calculation of transformer, HT/LT breaker, VCB, ACB, Switch gear requirement up to
cable size; Plant luminaries system design based on lux level requirement to optimize the power
consumption and use of natural lighting


Copyright © 2003 - 2015 Smartech Global Solutions Ltd. All rights reserved. Designed by Plastemart.com