• Gender: Male
• Age: 44
• Designation: Production Head
• Highest Education Level: Graduate - Degree
• Preferred Country: India
• Notice Period: 30  Days
• Preferred Location: Satara
• Work Experience: 21.3 Year(s)

Education

Bachelor Degree in Industrial Engineering from Indian Institution of Industrial Engineering, CBD Belapur, Navi Mumbai

Skill Sets

Production Planning & Control, Strategic Planning, Quality Assurance& Control, Process Enhancement, Productivity Improvement, Resource Management

Work Experience

Production Head
Since Feb 2017
Job Profile :
Supervising the manufacturing and supply of wiper motors’ products to global automotive companies including Renault Nissan, Volkswagen, Tata Motors, Maruti, Damiler
Monitoring daily production planning & management, line balancing & optimum resource allocation for day-to-day operations
Developing & implementing production plans and ensuring timely accomplishment of production targets; implementing measures to achieve substantial reduction in terms of cost and energy consumption
Implementing quality systems / procedures as required by ISO/IATF in the organization to reduce rejections and ensure zero defect products
Making preventive maintenance plan in month of March every year to ensure targets are met on time
Ensuring each machine has a machine history card and critical spare parts to ensure zero breakdown situation & smooth operations
Planning, scheduling and ensuring smooth Plant Operations, within budgetary limits, and as per Standard Operating Procedures (SOP)
Managing the individual shift production and monitoring Daily Progress Reports (DPR’s) as per schedule
Directing, leading and motivating workforce; imparting continuous on job training for accomplishing greater operational effectiveness/ efficiency
Administering high volume manufacturing of more than 40000 products per month
Spearheading complete operations for accomplishment of top and bottom-line profitability; directing complete operations of plants with responsibility for strategic utilization & deployment of resources
Ensuring complete compliance to Sustainable & Health Safety & Environment Policy  (SD & HSE, ISO 14001, OHSAS)  & procedures and providing necessary inputs to upgrade already existing standards
Presenting plant performance in MRM with action plan of failures
Confirming that 5S and TPM is being followed in the given work area and maintaining production related documentation
Assuring:
Implementing KAIZEN, 5S & TPM
Continual Improvements for PQCDSM
Disposal of scrap material on monthly basis

Plant Lead (Assembly & Welding Shop)
Mar 2015 to Feb 2017
Job Profile :
Managed 1 Sr. Engineer, 2 supervisors and 20 workers engaged in standard product production activities for Internal Tower Components

Senior Engineer Production (Assembly Shop),
May 2011 to Mar 2015
Company Name : Larsen and Toubro Ltd. (EBG Group)
Job Profile :
Managed a team of 2 supervisors and 44 workers engaged in production activities for Vaccum Circuit Breakers,Control panels (Switchboards)

Senior Engineer Production (Machining Cell)
Apr 2009 to Apr 2011
Company Name : Schrader Duncan Ltd.
Job Profile:
Managed a team of 3 supervisors, 3 line leaders and 42 workers engaged in production activities for Tyre Tube Valves,

Engineer Production (Assembly Shop)
Apr 2006 to Apr 2009
Company Name : Varroc Engineering Pvt. Ltd.,
Job Profile :
Managed a team of 16 workers engaged in production activities for Wiper Motor,Starter Motor,Flywheel Magneto

Engineer Production (Press Shop)
Aug 2003 to Mar 2006
Company Name : Walker Exhaust India Pvt. Ltd.,
Job Profile :
Managed a team of 6 Engineers and 14 workers engaged in production activities for Exhaust Control (Silencer and Catalytic Converters)

Trainings
Attended trainings on:
Principles & tools of kaizen by Nagar road, association industries held at Milton Plastic Ltd., Pune
Welding technology, BOS, JIT, SMED, supermarket, kanban, 5W1H
Tenneco Automotive 8D, 3M, Lean manufacturing, VSM, Pokayoke


Notable Accomplishments Across The Career
Ensured machine loading plan and capacity planning and resources requirement are ready by 25th of every month
Successfully reduced equipment downtime by over 50% and labor costs by 2.33 Lacs per year through SMED implementation
Achieved PPM level of 2500
Maintained yield to 90% & OEE to 80% for all line production.
Secured bottom-line savings of Rs.23.562 Lacs per annum through 14% headcount reduction through optimized manufacturing process & controls
Optimized productivity by 30% through development and implementation of continuous product flow line using lean manufacturing methodologies while working in Pricol Wiping Systems India Ltd.
Implemented Kanban Signaling System which balanced the line work fluctuation and reduced the overtime & costs
Planned & ensured proper execution of new projects
Successfully implemented single piece flow in production line, Implementation of kaizen system, Implementation of poka-yoka (mistake proofing) system
Optimized productivity by 10% through development and implementation of continuous product flow line using lean manufacturing methodologies while working in Walker Exhaust India Pvt. Ltd.
Identified business waste such as over-production, waiting, quality / defects, over-processing, under-utilized resources, inventory, movement, transportation and lack of maintenance; prepared the action plan to enhance the customer delight
Improved process to reduce the direct labour & consumable cost; which lead to cost saving of 10.68 lacs per annum
Suggested new tools, process, method and control for quality improvement of power press machines, sheet metal work & various welding machines like mig, tig, resistance while working in Walker Exhaust India Pvt. Ltd.

Profile Summary
Result-oriented professional offering experience in managing Production Operations, Production Planning & Control, Process Enhancements, Quality and Manpower Management with key focus on top line & bottom line profitability by ensuring optimal utilization of resources
A keen planner & executor with exposure to managing the entire production operations, devising process standards, process improvements and customer satisfaction
Proficient in assembly of wiper motor, assembly and welding of internal tower components, vaccum circuit breaker, control panels, machining of tyre tube valve, sheet metal fabrication of silencer
Proven skills in managing Quality Systems for meeting the standard requirements of the pre-defined guidelines using tools like Kaizen, Poka-yoke, 5S, Lean Management Tools, Kanban, SMED, 5W1H on Wiper Motor Line
Skilled in preparing bar charts, OEE, shift schedules, monthly plan, weekly plan, daily plan along with cell display boards
Expert in analyzing processes, identifying improvement areas & implementing techniques for reduction of rejection level, rework & consumption of resources
Possesses Excellent analytical, troubleshooting and inter-personal skills with proven ability in driving numerous quality enhancement, process improvement & cost saving initiatives