Mandar Desai available

Mandar Desai

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

Profileimage by Mandar Desai Freelancer in Process Engineer, Six Sigma Black Belt, PFMEA Expert. from Nashik
  • 422101 Nashik Freelancer in
  • Graduation: BE Production, Six Sigma Black Belt
  • Hourly-/Daily rates:
  • Languages: English (Limited professional)
  • Last update: 18.10.2020
Profileimage by Mandar Desai Freelancer in Process Engineer, Six Sigma Black Belt, PFMEA Expert. from Nashik
  • 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.
  • 01/2020 - 06/2020

    • PSA Group
    • 1000-5000 employees
    • Automotive and vehicle construction
  • Senior Manager (Powertrain Plant)
  • 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

    • General Motors India Pvt. Ltd.
    • 1000-5000 employees
    • Automotive and vehicle construction
  • Manager (Assembly & Testing)
  • 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

    • Mahindra & Mahindra Ltd.
  • Assistant Manager
  • 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

    • Mahindra & Mahindra Ltd.
  • Graduate Apprentice Trainee - Process Engineer in Central Manufacturing Engineering Department