Indian Production Engineer seeks opportunities

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Serial No: 9150

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Short Bio:

Successfully reduced the Chassis Trim related V1 concerns from 21 concerns to 3 concerns /month using FMEA concepts
• Achieved GK score of 4.3 against 4.3
• Effectively implemented 30 & 34 JPH job allocation
• Improved the direct pass of WeGo Vehicle from 53% to 72% in the FY 2009 – 2010
– XLN Vehicle from 93% to 97.4% in the FY 2008 – 2009
• Enhanced the capacity of moped vehicles from
– 300 to 600 vehicles / shift (2010 – 2011) for WeGo
– 700 to 1000 vehicles / shift (2009 – 2010) and improved V/M/D from 7.8 to 8.2 (Oct’09to Dec’09)
– 500 to 700 vehicles / shift (2008 – 2009)
• Efficiently managed the implementation of Kitting for Moped & WeGo vehicles

Current location:  Tamil Nadu, India - View on map

Preferred Sector of Employment:  accounting and finance

Spoken languages: Basic German and French, english

Location I am interested in working: Anywhere

PROFILE

Highly sophisticated and detail-oriented Engineer with over 6 years of extensive experience in Production Engineering – Quality Management and Production for Vehicle Assembly, now seeking challenging accountability to achieve the objectives of the organization. Proficient at focusing on strengths to stimulate personal and group/team excellence, build talent and deliver project results. Ability to take control of a situation and make decisions.

Proven competency to instill vision to achieve company goals and surpass management expectations while maintaining quality and customer service integrity through total quality management.

A keen planner & true believer in teamwork with expertise in establishing & managing operations with key focus on ensuring optimal utilization of resources. Exceptional knowledge of Process Failure Mode & Effect Analysis, TPM & TQM Concepts, Manufacturing Cost Evaluation, QC Story Methodology for problem solving, SOS preparation & modification, PPAP approval for New Product, and OEE/Conveyor utilization, calculation & improvisation; spearheading new initiatives; and transforming innovative ideas into immediate action.

Proficient in working on SAP environment for PLM. Expertise in designing layouts, material handling facilities, time study, manpower and investment planning. Excellent professional track record in planning and delivering assembly line facilities for new products, catering to high volume at minimal lead time and zero process rework.

A thorough professional with excellent communication, problem solving and analytical skills, along with the ability to multitask effectively under challenging/demanding conditions.

KEY SKILLS

• Quality Management

• Quality Assurance and Control

• Quality Function Deployment

• Production Operations & Optimization

• Vendor Development & Management

• Project Management

• Training & Development

• Relationship Management

• Process Improvement

• Target Achievement

• Strategic Planning

• SMM Reduction

• Line Balancing

• Grievance Handling

• Issue Resolution

CAREER CONTOUR

Organization Designation Duration

Renault Nissan Automotive India Private Limited [Micra / Sunny / Scala / Duster / Terrano / Stile – Chassis Trim / Prefinal Line] Senior Engineer – Production

[Trim & Chassis] Mar 2011 – Till Date

TVS motor company Ltd

[Moped & Scooter – Vehicle Assembly] Member – Production Engineering [Quality Management] Apr 2008 – Mar 2011

Gammon India Ltd [Jindal Civil Works Project] Junior Engineer – Plant Maintenance Sep 2007 – Mar 2008

EXPERIENCE

In Production Engineering

• Oversee production operations (planning, control & troubleshooting) in collaboration with a team of 26 members

• Monitor the progress on production and ensure the achievement of daily and monthly targets

• Achieve daily quality targets, including vehicle DPHU and internal customer complaint (V1)

• Adhere to compliance norms with desired quality and timely delivery of orders

• Conduct regular audit on unsafe conditions / acts, thereby ensuring zero accidents

• Oversee and minimize performance bottlenecks to achieve high productivity with minimum consumption of material & machine and monitoring expenses

• Identify areas of quality failures and implement steps to rectify the system

• Formulate quality standards to improve the quality of products and services

• Handle manpower and ensure execution of various jobs to achieve the targets within the stipulated time

• Develop new process concepts for production optimization, yield improvement as well as guidelines to streamline manufacturing activities / process

• Direct and lead the technical personnel

• Impart continuous on job training to the workforce and ensure achievement of greater operational efficiency

• Attend and resolve customer complaints pertaining to AVES (Alliance Vehicle Evaluation System), Static test, Dynamic test, and Shower test

• Monitor the DPU status of Chassis Trim zone

• Manage the implementation/follow up/closure of all PCR/CMS/KNOW HOW Sheet

• Identify and implement NVA kaizen through Walking Step Reduction Layout modification

In Quality Management

• Track external customer complaints and implement M2 to M5 action, accordingly

• Install in-house gates for Customer Complaint through “Can & Can’t Check Methodology”

• Reduce

o Overall Vehicle rework through “QM 10 Step Methodology”

o Vehicle assembly related rework through “Miharasen Zero Defect Methodology”

• Conduct assessment of quality performance in production areas along with analysis of production goals verses quality and cost objectives

• Analyze internal & external quality related concerns, conduct root cause analysis, and implement counter measure

• Gather and analyze the vehicle rework data on shift basis for continuous improvement through daily PDCA

• Adhere to process and TMOS & QCPC standards

• Generate problem analysis report for internal & external customer compliant / rework

• Monitor and optimize the manufacturing processes

• Collaborate with other departments to troubleshoot issues of new product development and efficiency

• Prepare and update QC inspector’s skill matrix, as well as, ‘Q’ charts

• Chair MOM along with suppliers on Q issues

• Ensure system adherence to safety standards, TS-16949, 7QC tools & KAIZEN Concepts

• Issue QJO to inter departments for any quality issue

• Conduct In-house PDI audit

• Control & closely monitor the daily line rejection & provide control plan to minimize the same

In Online Engineering

• Obtain PPAP approval for new project implementation

• Perform PFMEA on new product in coordination with Production Engineering Department

• Prepare and update TMOS and Rate routing

• Implement mistake proof system through Poka yoke

• Carry out process mapping of assembly line for a particular model, including Process Flow Diagrams,

• Prepare process flow sheets & work Instructions, operation wise, resulting the standardization of process

• Create new fixture design for conveyor system of new models

• Update existing fixture maintenance through “Fixture TPM”

• Oversee fabrication activities of Jigs/Fixtures, including planning, control & trouble shooting

• Coordinate in totally new assembly line facilities for TVS WEGO (new product) in Hosur Plant catering to a volume of 1000/day

• Review the QP phase of new product along with updation of PFMEA, QCPC, FMD and TMOS

• Prepare T-Matrix to identify the stage, to prevent defects

• Estimate CAPEX & REVEX of vehicle assembly for the financial year

• Monitor the consumption pattern of tools and other consumables

• New development and defining the new Process through Process qualification & Validation

• Involved in budget requisition and obtaining approval for shop floor improvement activities

• Perform calibration of special equipments and instruments, as per the calibration frequency

• Integrate IT with the Chassis number for assembly parameters

• Schedule the audit of pneumatic tools, torque wrenches and inspection gauges calibration