Ref. No. : CA - 29022 - (Production – with 25.3 years in Plastic Industry)

Education

4 years B. Tech. Mechanical Engg. From Regional Engg. College, Jalandhar.

Skill Sets

Experience in the areas of production operation, production planning and control, process improvement, quality assurance, maintenance & people management.

Quality Certifications: Certified for Internal Auditor -ISO/IATF 16949:2016 and ISO9001:2015

Attend training program on Lean /6 Sigma green belt and TPM and visual management.
Attended Two-day Training Program on Total Quality Management.
Successfully completed training on internal auditor for ISO/IATF 16949:2016, ISO9001:2015.
Computer knowledge: MS office, Power points, Minitap, SAP

Work Experience

Plant Manager
Since March 2019
Company Profile : Manufacturer of High tech, tight tolerance engineering components for automobiles, health care and agriculture industries.
Job Profile :
Production Planning & Control:
Managing production operations involving preparation of production plans & schedules to ensure timely accomplishment of production targets within Required Productivity, quality and cost parameter.
Ensure smooth movement of raw material from store as per daily requirement with identification as per standard colour code chart to avoid any mixed-up during manufacturing and FIFO and Ensure traceability of manufacturing production as per process flow diagram w.r.t. invoice number and process batch number.
Analysing production report process stage wise on a daily basis for Plan vs Done, material shortage, machine breakdown and monitor Production execution to meet the dead line.
Monitor the availability of inputs like raw material, tooling, and other consumable for production with store and take appropriate action to control inventory management program.
Prepare and Monitor annual budget of organization for short term and long-term business plan and establish KPI department wise and take counter measure to meet the Objective.
Monthly and weekly production planning with customer and vendor to resolve delivery schedule and ensure Min –Max inventory level (Kanban system) as per contract agreement with customer.
Material Procurement:
Ensure the capability of vendors in meeting with process and customer requirement and enlisting them as certified vendors.
Ensure Raw material procurement from supplier in time to avoid line stoppage with lead time calculation and regular follow up with supplier for bought out parts schedule.
Ensure the implementation of packing standards of material with cost analysis to avoid any damage during transit.
Production Operations
Review Daily Plant MIS & Derive the reduction of cost of poor quality and implementation of LEAN by elimination of wastage and Reduce variation in the process with Quality tool like Control chart, Graphs, Cause and Effect analysis, Pareto Charts, why-why analysis, with CFT.
Review process capability for critical product parameter, cycle time study, design of experiment by conducting trials, designing quality plans, standard operating procedure, control plan and analyze to ensure products meet customer requirements.
Redesign work process to achieve high value –added through value steam mapping, talk time for continuous flow.
Ensure the implementation of manufacturing documentation such as work instruction, quality plan, safety instruction to support existing processes and equipment in accordance with ISO/IATF:2016 and ISO9001:2015 requirements.
Monitor KPI like power consumption, machine efficiency, and product quality and manpower efficiency as per QMS.
Liaison with external and internal agency for the smooth running of plant and ensure compliance for legal requirement.
New product Development:
Review New drawing and standard as per customer requirement, RFQ, technical review with customer and monitoring of time plan for the new product submitted to customer.
Provide assistance in procurement of gauges and fixture for new product development. & validation of measuring instruments, jigs and fixtures & special Processes.
Coordination of new product release implement and preparation of APQP and submission of PPAP for customer approval with first article report, GR&R and SPC, etc.
Maintenance Management
Developing and implementing plans & schedules for maintenance operations with focus on optimum utilization of manpower and material and maintain proper inventory for spare.
Responsible for the implementation of MY MACHINE (AUTONOMOUS MAINTENACE), 5S (Visual control management), TPM concept for healthy running of machine & to minimize m/c breakdown.
Managing the functions of troubleshooting and preventive/breakdown maintenance of utilities, so as to reduce downtime to minimum up to 2% max.
People Management
Monthly Review of training record for Skill improvements & multiskilling of existing manpower and staff
Imparts training on 5S, SPC, Six sigma, 7QC tool, PFMEA, My Machine concept, TPM, OEE.
Project Undertaken
Productivity Improvement with Lean and six sigma with lean methodology (Target 15 part /month)
Improving machine utilization >90%
Preservation of finished and semi-finished product.
Achievement:
Reduce COPQ from saving 30.0 lakh to 9.0 lakh.
Delivery Achievement up to 98
Productivity improvement >90%
Machine breakdown reduce below 2.0%.
Reduce internal rejection PPM from 20 K to 6K & Customer PPM from 7K to 0.5K. in 2019-20

Assistant General Manager
Nov 2016 to March 2019
Company Profile : Manufacturer of Highly Precise Shafts, Sheet metal components, Gear wheel, Pinions and gear boxes assembly for Automotive, Aerospace, Industrial Automation for USA, Switzerland, and Germany & U.K.

Manager
Oct 2011 to Oct 2016.
Company Name : M.K AUTO CLUTCH CO.
Company Profile : Engaged in manufacturing clutch plates, clutch plate assembly, brake shoe, disc brake pad, pressure plates and pressure die cast for two-wheeler and three-wheeler markets. MK Group is a major supplier to almost All OEM in India like Royal Enfield, Bosch, SKF, Atul Shakti, fedral mogul. The brand MK is synonymous to CLUTCH PLATES and MX to brake shoe. MK Group have established manufacturing facilities like, High Pressure die casting, Compression Molding, MIG welding, shot blasting, seven tank cleaning and Machining etc.

Assistant Manager (Production)
March 2008 to September 2011
Company Name : Ind-Sphinix Precision Ltd
Company Profile : Is an ISO9001:2008 certified company engaged in manufacturing of PCB Drill , router and micro machining tools, set up in joint venture with SPHINX WERKE MULLER AG , Switzerland a pioneer in the field of micro drills, product range include a variety of tungsten carbide tools include micro drill and micro end mills, micro reamer for automobile ,aerospace ,ball pen industries & intra oculars lens industry. Ind-sphinix hold major share of Indian market besides exporting more than half of its product in EAST ASIA, USA, UK, JAPAN, KOREA, Germany & Others.

Senior Production Engineer
December 2005 to March 2008.
Company Name : Continental Device India Ltd
Company Profile : Is an ISO/TS16949, ISO 9001 quality management system as well as ISO 14001 environment system. The company is engaged in the manufacturing of semiconductor devices. Our main products are transistor, diodes, rectifier, thyristor chips/dices. The main supplier of our company is ST Micro electronics, Honey, Astec, etc.

Senior Quality Engineer
May 1999 to December 2005.
Company Name : Bajaj Sons Limited
Company Profile : Is an ISO/TS 16949 company engaged in the manufacturing and OEM Supplier of Auto parts for Hero Honda, Munjal Showa, Bajaj Auto, LML, Majestic Auto, Rico Auto Etc. Our main product is brake cam, sleeve rear wheel, brake rod, bracket, push rod tensioner, shaft rocker arm, pulley ring main, steering bracket etc. Bajaj Group has have all manufacturing facilities like, CNC Machining, Press shop, Thread Rolling, Thread Milling, SPM, MIG Welding assembly, Hot Forging and Plating .etc.

Core competencies
Lean Implementation, Productivity Improvements, People management, COPQ Control, Tooling management, Cost Optimization, Risk management Quality management system, Lean Implementation, Production management, Plant management, Supplier management

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