Profileimage by Mandar Desai Freelancer in Process Engineer, Six Sigma Black Belt, PFMEA Expert. from Nashik

Mandar Desai


Last update: 18.10.2020

Freelancer in Process Engineer, Six Sigma Black Belt, PFMEA Expert.

Graduation: BE Production, Six Sigma Black Belt
Hourly-/Daily rates: show
May Vary depending on Project Scope & Working time.
Languages: English (Limited professional)


  • A Six Sigma Black Belt Certified Professional offering over 13 years of rich and qualitative experience in driving end-to-end manufacturing, assembly, testing and troubleshooting of Engine.
  • Proven expertise in performing assembly & testing projects for Powertrain while ensuring adherence to defined quality parameters & timelines.
  • Led continuous improvement projects such as Value Engineering Projects, Multi Spindle Torqueing Solutions, Kaizen Projects for reducing operating costs.
  • Highly skilled in enhancing operational efficiency and continuously improving effectiveness of processes by analyzing Cold test & hot test data
  • Strong record of success in managing advance engineering projects  related with process improvement (line rejection, assembly line rejection  & process audits), productivity improvement & quality improvement.
  • Conducted the DC tool programming as well as leveraged experience with Bosch-Rexroth & Altas Copco tools as well as facilitated Q trance programming.
  • Process documents development - PFD, PFMEA, Control Plan & Defect mapping strategy.

Project history

01/2020 - 06/2020
Senior Manager (Powertrain Plant)
PSA Group (1000-5000 employees)
Automotive and vehicle construction
Projects Completed:
* Planning of entire line for 100K + 300K volume
* Planning of End of line test bed
* Compact End of line test bed (Fire test bench) Installed

Key Result Areas:
* Participating as a team player to align Indian market with PSA brand
* Supervising the progress made in the :

o 100K Powertrain line and ensuring that the project is completed by the end of 2020
o Upcoming model 300K capacity line which is to be completed by 2021
* Managing complete Assembly & Testing operations for Engine, supported by a team of Engineers
* Setting-up product & component assembly lines involving preparation of RFQ for capital equipment, finalization of
specifications, capital-purchase requisition, finalization of orders, facility planning and commissioning
* Developing & releasing Process Design for existing / new processes (involving development of FMEA, Control Plan, Layout
Preparation, so on)
* Installing & commissioning all equipment in facilities; analyzing need for CAPEX; planning capacities based on equipment
* Providing support for Root Cause Analysis of product quality related issues; identifying solutions to improve cost, quality and
* Implementing Value Engineering methods for standardization and to reduce costs; controlling quality parameters as per FTQ,
PPM; facilitating technical audits and compliance with quality standards
* Promptly analyzing and resolving field complaints; developing action plan & improvement plan

12/2011 - 01/2020
Manager (Assembly & Testing)
General Motors India Pvt. Ltd. (1000-5000 employees)
Automotive and vehicle construction
Projects Completed:
* Assembly Line for Sail Diesel & Gasoline Engine
* Test Bed for Sail & Enjoy Engines
* Assembly & Testing for Export Models
* Engine Correlation & Pass Fail Significance with Cold Test
* Engine Test Systems - Cold Test & Hot Test for Petrol, Diesel & LPG Models
* Fault Tree Analysis for Cold Test & Hot Test with User Guide for Defect Mapping

Key Result Areas:
* Administered the implementation of new products with key focus on quality, cost & delivery in conformance to preset
technical specifications and as per deadlines & requirements as Program systems engineer (PSE)
* Led, motivated and managed cross-functional teams and drove engine assembly & testing projects to completion with limited
supervision as Manufacturing responsible engineer (MRE)

* Safeguarded adherence to preset quality standards and ensured zero defects; initiated throughput & OEE improvement
measures for process enhancement
* Conducted the DC tool programming as well as leveraged experience with Bosch-Rexroth & Altas Copco tools as well as
facilitated Q trance programming
* Collaborated with the management as well as shared the trends and operational issues and areas of focus in a timely manner
with them
* Monitored the daily meetings/communications to ensure active participation of all employees that are assigned to specific
projects as well as conducting weekly safety meetings with team members
* Anchored complete installation and commissioning of equipment; studied & analysed blueprints, technical drawings and
* Minimized unplanned downtime, identified opportunities for improvement; reviewed the operation of plant equipment and
systems constantly, executed projects that improve efficiency and/or reduce operating costs

* Bagged:
o President Award for Throughput Improvement in Testing
o Transformer Award for Tappet Throughput Improvement in 2015
o Transformer Award for Hot Test Localization & Cost Saving in 2016
o Red - X Tool Certified Coach in 2017
o Employee of the Year in 2019

05/2008 - 12/2011
Assistant Manager
Mahindra & Mahindra Ltd.
Projects Completed:
* Development of common leak testing machine for four different models on mHawk engine assembly line
* Cycle time reduction to 50% by development of Quick release coupling in leak testing machine
* Installation and commissioning of testing facilities for mHawk & mEagle engines and their variants (Overall 11 test beds)
* Common Test Bed for Diesel & Petrol and 85 KW, 103 KW engines
* Capacity enhancement 100% by development of Quick change coupling direct on engines
* Development of injector code flashing software
* Auto switchover of ECU as per engine selection

* Received Letter of Appreciation from President, Auto & Farm Equipment Sector for "Refurbishment of Old Vauxhall Line for
Phase 1 Engine Testing"
* Led the implementation of hot firing for first time in Mahindra & Mahindra Ltd.
* Steered productivity improvement for test bed
* Developed engine testing facility for testing engines with Dual Mass Flywheel

04/2007 - 04/2008
Graduate Apprentice Trainee - Process Engineer in Central Manufacturing Engineering Department
Mahindra & Mahindra Ltd.

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