• Gender: Male
• Age: 43
• Designation: Team Leader
• Preferred Country: India
• Work Experience: 15.6 Year(s)

Skill Sets

Plastic Component & Mould Development
Techie with 11 years proven track record of strong, decisive executive leadership in Production Management, Maintenance, Quality Assurance & Supply Chain Management.
Proven abilities to enhance the process operations optimize resource & capacity utilization; escalate productivity & operational efficiencies; while curtailing the costs/ expenses. 
Adept at supervision, co-ordination and managing the day-to-day and round the clock operation and maintenance of all specialized services. 
Proficiencies in managing maintenance operations of Equipment and Utilities in Manufacturing Facilities with proven abilities in reducing downtime and enhancing operational efficiencies.
Extensive background in complex and challenging environments with proven ability to represent the company with Customers and Strategic Vendor Partners.
Domain expertise in Plastic Mould Development i.e. Feasibility to Approved Component. 
Coordinating projects for the set up faci

Work Experience

Team Leader - Injection Moulding, Molds & Assembly lines 
Since March 2013 To Till Date.
Company Profile: Leading Manufacturer of Plastic household items, food storage containers sets.
Job Profile:
Setting up a production facility .
Overseeing all production activities from incoming materials to outgoing products
Defining assembly process and procedures.
Hiring a team of technicians, supervisors and administrators to implement all activities.
Developing a quality plans and ensuring compliance with all quality procedures.
Maintaining appropriate levels of inventory to meet production plan.
Identifying and qualifying new vendors.
Ensure daily output according to production plan.
Deliver required product quality and continuous improvement.
Attend the Monthly Management meetings as part of the management team.
Collaborate with the QA department to improve our reject rates and capability of processes.
Develop skill base of the people and ensure the skills matrix are updated with HR function.
Manage the grievance & disciplinary process with HR for all production employees.
Control the output to the targeted level and ensure all specifications are achieved
Hold regular reviews with the workforce and brief them of any manufacturing issues.
Develop skills analysis and matrix for supervisors and engineers.
Head the daily departmental meeting and participate in daily meetings
Sign off new process installations before start of production from process engineering.
Plan for labor requirements and authorize holidays for the department.
Identify areas of opportunity for continuous improvement in the future.
Follow factory layout for best material flow.
Decrease work in process.
Ensure the mold maintenance team kept the tool in best possible working conditions
Participating in new projects realization (APQP)
Participating in new process development.
Continuous improvement of process productivity.
Delivery of headcount reduction and cost reduction targets.
Ensure of budget phasing for the department.
Keeping track of the recent technical developments in the fields related to the products being developed in-house.
With team, Provide training programme s in line with business plan requirements.
Developing relationships with key RM suppliers to keep abreast of potential new technologies.
Represent by maintaining contact with external organizations and individuals and by attending meetings, training's and conferences.
Ensure completion of Project Plans to achieve the above with regular monitoring/tracking of milestones ensuring targets is fully met.
Keeping track of the lessons learned during development and sharing those with other team members.
Motivation of team members to ensure efficient output of the team and challenging others to develop as leaders while serving as a role model and mentor.
Key performance objectives: scrap rate, right time first, raw material and energy consumption and labor efficiency. Ensure the defined Objectives are achieved or met

Production In-Charge – Injection Moulding & Molds
Dec 2007 to July 2012
Company Profile : Manufacturer of Power distribution & control, Electrical Switches & Sockets, Cables & Wires, Transformers, Lighting etc.
Job Profile : 
Responsible for overall performance & growth of the Moulding section
Lead the injection production unit, making and delivering products to its customers, according to the safety, quality, cost and timing requirements and in line with objectives of industrial performance of the factory
Takes part in the implementation of the progress step and staff involvement notably through the implementation of tools and through their follow up
Conduct the Mould Trails. Corrections & Proving the mould
Mistake proofing Mould making to make hassle free shop floor.
Leads a daily production meeting, adjusts its resources according to the changes, implements and makes sure of the efficiency of the corrective actions. 
Report on timely basis to executive management on the performance of the Production Dept., any non-compliance issues and recommended actions for NPD
Follows and optimizes injection process and results
Robot Operation Programming, Programs and configures injection robots, supervises IMM programming and setting
Effectively interact with Quality and Development teams to maintain product supply and help introduce new products
Participate in new products/new process (IMM, robots) launches.
Process set, control & standardization in high speed automatic production line.
Stabilizes and optimizes injection moulding results (ppm, plastic consumption, scraps) and follows actions plans
Analyze process failures causes
Planning to reduce non availability of tooling
Analyze paint defaults/scrap in paint due to injection process
Propose, test and validate technical solutions in order to improve injection performance(productivity, quality, safety)
Conduct DOE for New Moulds. (Hot Runner Mould with Multi Core Operations)
Applying engineering changes, CNC and EDM programming
Mould BOM Creation.
Facilitate and oversee the creation of Production documentation throughout including FMEAs, Control Plans, SPC, flow charts, etc.
Provide leadership for developing and directing improvement initiatives (Cost-of-Quality reductions, Audit system, CAPA system, etc.) for all products & processes
Maintaining Kanban system in Gas Assisted Injection Moulding Process shop floor
Monitor & review the improvement Projects taken for Reduction of Scrap/Cycle Time
Ensure inventory levels meet management expectations and achieve superior cost saving and high degree of implementation of Material management techniques
ECR Generation with accurate back flush data and implement the ECO w.r.t. ECN
Develop, implement, communicate and maintain SOP to bring the Production Systems and Policies into compliance with QMS requirements
Recognize, interpret, and evaluate inconsistencies, discrepancies, and inaccuracies in the various products, and appropriately clarify and/or report them as required

Achievements:
Process rejection Reduced in gas moulding products from 7.2% to 1.6 %.
Material wastage reduced to 4% with the help of lean six-sigma, Kanban and 5 ‘S’.
Completed 02 Six-sigma GB Projects.

Engineer - Production in Plastic Moulding Shop 
Jul 2005 to Nov 2007
Company Name : Videocon Industries Limited
Job Profile : 
Injection moulding management & process improvement.
Day to day process trouble shooting in conventional and GAIM process.
Manpower management
Ensuring Quality Assurance.
Manpower control.
Production planning and control.
To implement various methods of improvement
Monitored Process Performance Indicators like Cp, CpK, internal PPM, supplier PPM
Co-coordinating with other dept. for getting better results for DOL.
Make practice of 5S’s by Self & Sub-ordinates.
Providing Training to Operator for better output & Quality.

Associate Member - Mould Shop 
Jul 2004 to Jul 2005
Company Name: Tata Auto Plastics Limited

Processing Equipments Handeled
Injection moulding machine i.e. LG, Jinhwa, Ferromatic Milacron, L & T (60~2700T)
ENGEL Hydraulics and Electrical machine (55~3000T)
PP injection stretch blow moulding machine. 
Extruder (Single screw, Co-rotating, counter twin screw extruder)

Raw Materials Processes 
Engineering Plastics (ABS, PC, PA6, PA66)
Commodity Plastics (HIPS, PP, PE)

Proficency Forte
Plastic Mould Development
The entire development process from the initial design meeting to delivery of the finished mold relies on meticulous engineering and planning. 
Design review of plastic moulds w.r.t. the Polymer to be processed
Trials and trouble shooting of moulds
Setting up the Tool room systems and procedures
Responsible for upkeep of the tools, molds, spares development with incoming Raw materials, developing jigs, small tools, fixtures
Maintaining tool room equipments & design the maintenance plan
Setting up Tool room Deliverables, process parameters, checks
Setting up the systems at vendors locations, vendor audits, Vendor Development for better procurement of Moulds or auxiliary parts
Communicating with internal and external customers with respect to quality matters & responsible for internal audits. 
Contributes in necessary actions to solve product quality issues
Training and developing associates, employees and driving organization culture for better Mold Manufacturing & Assembly 
Well versed with all types of tools being used in industry (carbide drills, insert drills, all types of inserts, cutting tools like hobs, shaving cutter, shaping cutter, broaches, grinding wheel, etc.) along with their designs and geometry of cutting
Exposure of tool & mould manufacturing conventional and CNC machines, EDM Machines, Lathe Machines, Milling Machines, Wire EDM Machines, Grinding Machines, Polishing Equipment, Welding Equipment
Proper & correct utilization of jigs /fixtures
Mold verification and validation through FAIR (first article inspection report) for every cavity