Engineer - Production (Press shop)
NEEL Industries Limited (JBM group)
Keywords
AutoCAD
Failure Mode Effects Analysis
Manufacturing
SAP Applications
Skills
Greenfield, Brownfield projects, tryout 2, tryout 3, FMEA, AutoCAD, Microsoft word, PowerPoint, SAP
Project history
10/2022
-
10/2022
Nature of Job :
? Exposure in sheet metal Pressed components & welded components
? Customer complaints are addressed
? 5s activities -Zonal leader
? Follow up activities with QC/PPC/TOOL / Maintenance/ Development
? Daily Production plan and monthly performance report
? Training attended on Gemba Kaizen, 5S Techniques, 3M, My Machine concepts
Trainings attended:
? MOST - Maynard Operation Sequence Technique (work measurement tool).
? PFMEA & MFMEA - Process & machinery failure mode Effects Analysis
? MSA, Poka-yoke, Gemba Kaizen, LCA, Ergonomics.
? Exposure in sheet metal Pressed components & welded components
? Customer complaints are addressed
? 5s activities -Zonal leader
? Follow up activities with QC/PPC/TOOL / Maintenance/ Development
? Daily Production plan and monthly performance report
? Training attended on Gemba Kaizen, 5S Techniques, 3M, My Machine concepts
Trainings attended:
? MOST - Maynard Operation Sequence Technique (work measurement tool).
? PFMEA & MFMEA - Process & machinery failure mode Effects Analysis
? MSA, Poka-yoke, Gemba Kaizen, LCA, Ergonomics.
01/2010
-
12/2012
Manger - Lead for Assembly line integration
truck transmission (Greenfield project)
ii) From 2013 to 2014 - as Manger - Lead for Assembly line integration (combine medium duty
and heavy duty transmission line into single assembly line - (Brown field project)
iii) From 2014 to 2019 -as Senior manager - Lead for Planning and prove out assembly
facilities for Global Medium duty truck transmission (Green field project)
iv) From 2019 to till date - Senior manager - New projects -Engine Assembly
Roles and Responsibilities:
? Project lead for Powertrain assembly
? Provide budget estimate for all new Powertrain projects to the management
? Provide multiple layout scenarios for management approvals
? Submit Manufacturing engineering status to projects for each quality gate approvals
? Process planning for 5 mins takt time and do bench mark study with mother plant at
Germany, Japan and Brazil.
? Prepare of RFQ as per product requirements and do detailed technical discussion with
suppliers for the planning of equipments like End of line Test bed , Assembly Press , Nut
runners , Washing Machine ,Leak Test machine etc.
? Ensure all the suppliers are inline with the technical specifications and give recommendations
to purchase team for ordering process
? Approve the Design of the equipment (DAP) as per Technical specification
? Coordinate with suppliers and ensure the equipment readiness for equipment preacceptance
at supplier end
? Responsible for Installation and commissioning of equipments like conveyors, Assembly
Presses, Assembly line equipments as per planned takt time.
? Complete line prove out in three stages tryout 1 , tryout 2 and tryout 3 and ensure the line
readiness for SOP
? Ensure all the quality parameters meet as per the technical specification during prove out
stage
? Ramp up the assembly line as per the planned capacity and handover to production, quality
and maintenance
? Capitalize the planned equipment by meeting Financial requirements
? Design review and process review, Engineering change proposals with respect to Quality,
Safety & cycle time.
? Prepare, Evaluate & Finalize the Layout for Manufacturing Process as per Takt time
? Analyze station wise Safety & Ergonomics for the production line and implementing corrective
action.
? Prepare process related documents like PFD, PFMEA, Control plan, Audit documents for
Process & Product etc.
? Analyze the Maintenance accessibility & TPM related improvements in the equipments during
DAP stage & implementing corrective action in the equipment.
? Identify and implement Low cost automation
? QMS Lead auditor for Manufacturing Engineering ,Implementation of IATF,ISO 140001,ISO
450001,ISO 500001
ii) From 2013 to 2014 - as Manger - Lead for Assembly line integration (combine medium duty
and heavy duty transmission line into single assembly line - (Brown field project)
iii) From 2014 to 2019 -as Senior manager - Lead for Planning and prove out assembly
facilities for Global Medium duty truck transmission (Green field project)
iv) From 2019 to till date - Senior manager - New projects -Engine Assembly
Roles and Responsibilities:
? Project lead for Powertrain assembly
? Provide budget estimate for all new Powertrain projects to the management
? Provide multiple layout scenarios for management approvals
? Submit Manufacturing engineering status to projects for each quality gate approvals
? Process planning for 5 mins takt time and do bench mark study with mother plant at
Germany, Japan and Brazil.
? Prepare of RFQ as per product requirements and do detailed technical discussion with
suppliers for the planning of equipments like End of line Test bed , Assembly Press , Nut
runners , Washing Machine ,Leak Test machine etc.
? Ensure all the suppliers are inline with the technical specifications and give recommendations
to purchase team for ordering process
? Approve the Design of the equipment (DAP) as per Technical specification
? Coordinate with suppliers and ensure the equipment readiness for equipment preacceptance
at supplier end
? Responsible for Installation and commissioning of equipments like conveyors, Assembly
Presses, Assembly line equipments as per planned takt time.
? Complete line prove out in three stages tryout 1 , tryout 2 and tryout 3 and ensure the line
readiness for SOP
? Ensure all the quality parameters meet as per the technical specification during prove out
stage
? Ramp up the assembly line as per the planned capacity and handover to production, quality
and maintenance
? Capitalize the planned equipment by meeting Financial requirements
? Design review and process review, Engineering change proposals with respect to Quality,
Safety & cycle time.
? Prepare, Evaluate & Finalize the Layout for Manufacturing Process as per Takt time
? Analyze station wise Safety & Ergonomics for the production line and implementing corrective
action.
? Prepare process related documents like PFD, PFMEA, Control plan, Audit documents for
Process & Product etc.
? Analyze the Maintenance accessibility & TPM related improvements in the equipments during
DAP stage & implementing corrective action in the equipment.
? Identify and implement Low cost automation
? QMS Lead auditor for Manufacturing Engineering ,Implementation of IATF,ISO 140001,ISO
450001,ISO 500001
03/2007
-
05/2010
Manager - Manufacturing
Tata Motors Ltd
03/2007
-
05/2010
Manager (Power train shop Planning)
TATA MOTORS LTD; TVS Sundaram Fasteners Limited - Autolec division
Responsibility : Project management,Process & Equipment Planning, TATA NANO (1 Lakh
Car)
Projects Handled:
I. From 2007 to 2010 - Plan, execute and prove Transaxle assembly and testing facilities
(Green field projects)
KEY RESPONSIBILITIES
Working as a Small Car Manufacturing Planning Engineer and responsible for,
? Process planning for 52 sec takt time line of Power train Assembly for Small Car TATA
NANO (1 Lac Car).
? Preparation of RFQ and detailed discussion with suppliers for various equipments including
End of line Test bed , Assembly Press ,Multispindle Nut runners , Washing Machine ,Leak
Test machine etc.
? Analyze the equipment specifications and functionalities, sending the technical comparisons
and recommendations for further commercial negotiations by purchase representatives.
? Approving the Design of the equipment (DAP) as Technical specification
? Successfully Installed & commissioned equipments like end of line Test bed, conveyors,
washing machine, Assembly Presses, Assembly line as per takt time.
? Design review and process review, Engineering change proposals with respect to Quality,
Safety & cycle time.
? Preparing Work content for individual operators & Cycle time for individual Process using
MOST Techniques & Line balancing as per Takt time
? Preparation, Evaluation & Finalization of Layout for Manufacturing Process as per Takt time
? Analyzing station wise Safety & Ergonomics for the production line using Rula Analysis and
implementing corrective action.
? Preparing process related documents like PFD, PFMEA, Control plan, Audit documents for
Process & Product etc.
? Analyze the Maintenance accessibility & TPM related improvements in the equipments during
DAP stage & implementing corrective action in the equipment.
? Preparing JH schedule, PM schedule for all planned equipments.
? Tryout of complete line in singur plant
? Tryout of complete line of 90K project in pune.
? Successfully installed and Commissioned, Process proved at Singur,Pune and at
Sanand
? Successfully made PO, PP batches & ramped production upto 300 per day at Pune
Powertrain Production facilities.
? Reduced 15 manpower using Low cost Automation.
? Implemented the TPM procedures for Power train line equipments like preparation of MFMEA,
JH schedules, PM schedules, etc.
? As Team leader for 5 Kaizen events (3P - Production Preparation Process as called in Tata
Motors) along with Cross functional experts for achieving desired scope in TPM, LCA, and
Ergonomics etc.
? 63 Pokayoka Identified through Pokayoka exercise & Implemented in planning stage
? 854 Improvements identified through TPM activities & Implemented in the equipment
? 25 LCA identified & Implemented in the Production line
PREVIOUS EMPLOYER - Second
TVS Sundaram Fasteners Limited - Autolec division
Engineer - Production (Assembly shop)
Nature of work:
? Preparing weekly Plan, loading plan and achieving schedule Vs adherence
? Preparing SOP for all assembly processes
? Preparing Monthly performance report
? Deciding the Process Sequence as per the cell Layout
? Co-coordinating activities with QC/Maintenance/Tool room/PPC/Development/Purchase
? Submitting the Samples to the Customer and Getting Approval for the Same
? Working as an Team Member in Preparation of Production Part Approval Process (PPAP)
? Implementing Fail safe (poke- yoke) to meet the zero rejection
? Major contribution in Productivity improvement
? Handling fixtures equipments
? Knowledge in Production part approval process (PPAP), Statistical Process Control (SPC) and
Measurement Systems Analysis (MSA), FMEA.
TPM -Activities:
? Preparing Optimal Condition Check sheet for Presses...
? Preparing weekly rejection trend and taking corrective action.
? Conducting Awareness Program for Operators.
? Calculating OEE /OPE for critical Presses.
? Conducting 5S Audit in each cell.
50 Fail-safe implemented. Some of us below:
? Fail safe for ensuring oil hole opening for lubrication oil flow.
? Fail safe for socket retainer assy for lubrication oil flow
? Fail safe for interchanging position for intake valve and exhaust valve in assy.
? Fail safe for socket groove width identification
? Fail safe for roller height identification. Fail safe for oil hole opening
Car)
Projects Handled:
I. From 2007 to 2010 - Plan, execute and prove Transaxle assembly and testing facilities
(Green field projects)
KEY RESPONSIBILITIES
Working as a Small Car Manufacturing Planning Engineer and responsible for,
? Process planning for 52 sec takt time line of Power train Assembly for Small Car TATA
NANO (1 Lac Car).
? Preparation of RFQ and detailed discussion with suppliers for various equipments including
End of line Test bed , Assembly Press ,Multispindle Nut runners , Washing Machine ,Leak
Test machine etc.
? Analyze the equipment specifications and functionalities, sending the technical comparisons
and recommendations for further commercial negotiations by purchase representatives.
? Approving the Design of the equipment (DAP) as Technical specification
? Successfully Installed & commissioned equipments like end of line Test bed, conveyors,
washing machine, Assembly Presses, Assembly line as per takt time.
? Design review and process review, Engineering change proposals with respect to Quality,
Safety & cycle time.
? Preparing Work content for individual operators & Cycle time for individual Process using
MOST Techniques & Line balancing as per Takt time
? Preparation, Evaluation & Finalization of Layout for Manufacturing Process as per Takt time
? Analyzing station wise Safety & Ergonomics for the production line using Rula Analysis and
implementing corrective action.
? Preparing process related documents like PFD, PFMEA, Control plan, Audit documents for
Process & Product etc.
? Analyze the Maintenance accessibility & TPM related improvements in the equipments during
DAP stage & implementing corrective action in the equipment.
? Preparing JH schedule, PM schedule for all planned equipments.
? Tryout of complete line in singur plant
? Tryout of complete line of 90K project in pune.
? Successfully installed and Commissioned, Process proved at Singur,Pune and at
Sanand
? Successfully made PO, PP batches & ramped production upto 300 per day at Pune
Powertrain Production facilities.
? Reduced 15 manpower using Low cost Automation.
? Implemented the TPM procedures for Power train line equipments like preparation of MFMEA,
JH schedules, PM schedules, etc.
? As Team leader for 5 Kaizen events (3P - Production Preparation Process as called in Tata
Motors) along with Cross functional experts for achieving desired scope in TPM, LCA, and
Ergonomics etc.
? 63 Pokayoka Identified through Pokayoka exercise & Implemented in planning stage
? 854 Improvements identified through TPM activities & Implemented in the equipment
? 25 LCA identified & Implemented in the Production line
PREVIOUS EMPLOYER - Second
TVS Sundaram Fasteners Limited - Autolec division
Engineer - Production (Assembly shop)
Nature of work:
? Preparing weekly Plan, loading plan and achieving schedule Vs adherence
? Preparing SOP for all assembly processes
? Preparing Monthly performance report
? Deciding the Process Sequence as per the cell Layout
? Co-coordinating activities with QC/Maintenance/Tool room/PPC/Development/Purchase
? Submitting the Samples to the Customer and Getting Approval for the Same
? Working as an Team Member in Preparation of Production Part Approval Process (PPAP)
? Implementing Fail safe (poke- yoke) to meet the zero rejection
? Major contribution in Productivity improvement
? Handling fixtures equipments
? Knowledge in Production part approval process (PPAP), Statistical Process Control (SPC) and
Measurement Systems Analysis (MSA), FMEA.
TPM -Activities:
? Preparing Optimal Condition Check sheet for Presses...
? Preparing weekly rejection trend and taking corrective action.
? Conducting Awareness Program for Operators.
? Calculating OEE /OPE for critical Presses.
? Conducting 5S Audit in each cell.
50 Fail-safe implemented. Some of us below:
? Fail safe for ensuring oil hole opening for lubrication oil flow.
? Fail safe for socket retainer assy for lubrication oil flow
? Fail safe for interchanging position for intake valve and exhaust valve in assy.
? Fail safe for socket groove width identification
? Fail safe for roller height identification. Fail safe for oil hole opening
02/2006
-
03/2007
Engineer - Production
TVS Sundaram fasteners Limited
10/2004
-
02/2006
Engineer - Production (Press group)
Neel Industries Limited ( JBM; Daimler India Commercial Vehicles Limited
Local Availability
Only available in these countries:
India
