Omkar Bhoir Email & Phone Number

• Spearheaded the creation of a holistic preventive maintenance plan for a water district serving approximately 200 homes, focusing on infrastructure integrity, water quality improvement, and regulatory compliance. • Conducted thorough assessment of existing water system components, including wells, reservoirs, distribution networks, and fire hydrants, identifying critical areas for immediate intervention and long-term improvement. • Developed and implemented a comprehensive Water Quality Management Plan, encompassing regular testing schedules, filtration system upgrades, and systematic flushing programs to significantly enhance water quality for district customers. • Prioritized maintenance and replacement tasks for aging infrastructure, balancing urgent needs with budgetary constraints and future loan prospects, ensuring optimal use of the district's $49,000 surplus. • Designed emergency response and safety preparedness protocols, particularly addressing the potential failure risk of an aging reservoir and the replacement/refurbishment needs of critical fire hydrants. • Collaborated with KeelWorks professionals to showcase project management and problem-solving skills, demonstrating the value of expert consultation in municipal water system optimization and maintenance planning.

Hyderabad, Telangana, India

• Led optimization of DC link capacitor design and assembly processes using DMAIC methodology, improving product reliability by 18%. This data driven approach enhanced customer satisfaction and market competitiveness. Implemented comprehensive risk management strategies utilizing Failure Mode and Effects Analysis (FMEA), ensuring 100% adherence to quality and safety standards. This proactive approach improved product performance and company reputation.• Spearheaded engineering of critical components including aluminum containers and insulator bushings through strategic sourcing, enhancing product durability by 22%. This extended product lifespan, reduced maintenance needs, and improved customer satisfaction. Fostered cross-functional collaboration between design, manufacturing, and quality teams, ensuring seamless implementation of optimized components. Established regular interdepartmental meetings and clear communication channels resulting in efficient product development and reduced time-to-market.• Utilized advanced CAD tools for 3D modeling and 2D drafting, creating detailed models that improved communication between design and production teams. This enhanced visualization allowed early detection of potential manufacturing issues, reducing costly revisions. Played key role in continuous improvement initiatives by analyzing product performance data. Used statistical tools and root cause analysis to identify enhancement areas proposing and implementing design modifications that improved efficiency and manufacturability.• Collaborated with suppliers to optimize component designs for cost-effectiveness and performance. Conducted material analyses and durability testing to ensure components met or exceeded industry standards. Participated in design reviews, providing valuable insights on manufacturability and potential design improvements. Developed comprehensive documentation for all design changes, ensuring clear communication of modifications to relevant teams

Pune/Pimpri-Chinchwad Area

• Spearheaded initiative to optimize paint ratios across product lines, conducting extensive analysis of historical consumption data and performing controlled experiments with various formulations. Implemented lean manufacturing principles, resulting in 25% reduction in cycle time per batch and increased plant output capacity. Achieved 25% reduction in overall paint consumption through multi-faceted approach, including refined mixing processes, efficient application techniques like electrostatic spraying, and advanced paint recovery systems. This led to substantial cost savings and aligned with company sustainability goals.• Led implementation of statistical process control (SPC) methods to address coating thickness variations. Set up control charts, established control limits, and trained operators on real-time monitoring. This resulted in 15% decrease in scrap rates, improving resource utilization and reducing costs. Conducted in-depth root cause analysis to identify sources of coating thickness variation, using tools like Ishikawa diagrams, 5-Why analysis, and Design of Experiments (DOE). Developed and executed robust control plan including equipment calibration schedules and environmental control measures.• Collaborated with quality assurance team to establish new testing protocols for paint consistency and adhesion. Researched industry best practices, consulted with suppliers, and conducted extensive trials to determine optimal methods. This led to higher product quality, increased customer satisfaction, and reduced post-sale issues. Designed and delivered comprehensive training programs for production staff on new paint application techniques and quality control measures. Created visual work instructions and regular refresher sessions, fostering culture of continuous improvement.

Pune/Pimpri-Chinchwad Area

• Led transition of heater fuel system from diesel to Compressed Natural Gas (CNG), conducting comprehensive thermodynamic analysis evaluating heat transfer efficiency, fuel consumption, and emissions. Optimized CNG system achieved annual savings of INR 100,000 and significantly reduced carbon footprint, enhancing company's environmental reputation. Spearheaded major redesign of cyclone system through rigorous engineering analysis, involving CFD simulations, prototyping, and extensive testing. Implemented modifications resulted in 10% drop in sand temperature and 15% increase in processing efficiency, reducing energy consumption and increasing plant productivity.• Revolutionized resin coating procedure through detailed process flow analysis and implementation of advanced automated curing system. Mapped entire coating process, identified bottlenecks, and leveraged Industry 4.0 principles to introduce smart, connected equipment. Achieved 12% reduction in gel wastage and 33% improvement in cycle time per batch, translating to significant cost savings and increased production capacity. Established proactive maintenance strategy for new CNG system, collaborating with maintenance teams to develop comprehensive schedules for inspections, component replacements, and performance optimizations.• Conducted detailed cost-benefit analysis for fuel transition project, gathering data on fuel prices, equipment costs, and projected savings. Used advanced financial modeling to forecast long-term benefits and ROI, presenting findings to senior management with clear visualizations and compelling narratives to secure project approval. Developed and implemented new standard operating procedures (SOPs) for optimized resin coating process, including step-by-step guides, troubleshooting flowcharts, and quality checkpoints.

Nashik, Maharashtra, India

• Spearheaded quality improvement initiative in tool and sheet metal fabrication using poka-yoke (mistake-proofing) methodology. Conducted systematic analysis of production process to identify potential error points, designing and implementing error-prevention mechanisms including custom jigs, sensor-based checks, and visual management systems. Achieved 10% reduction in defects, decreasing scrap rates and improving resource utilization. Enhanced customer satisfaction for automobile press components through rigorous Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT). Developed detailed test plans, set up specialized testing equipment, and collaborated with internal teams and customers to identify and rectify surface finish issues.• Achieved 19% reduction in customer complaints through implementation of stringent quality control processes and proactive problem-solving. Analyzed historical complaint data, identified recurring issues, and implemented targeted improvements in manufacturing processes. Introduced customer feedback loop to address concerns promptly and prevent future occurrences, leading to improved customer retention and increased repeat business. Led cross-functional collaboration to analyze and address assembly errors, organizing regular meetings with design, production, and quality teams. Conducted root cause analyses and developed comprehensive solutions, including worker training programs focused on best practices in assembly techniques and quality awareness.• Drove improvements in fixture quality through data-driven analysis and iterative design enhancements. Used statistical tools to analyse performance data, collaborating with design team to implement modifications such as enhanced clamping mechanisms and optimized geometries. Established and chaired weekly quality review meetings, bringing together representatives from all departments to discuss quality trends and implement corrective actions.

Master'S Degree, Engineering/Industrial Management, 3.58

Bachelor'S Degree, Mechanical Engineering, 8.1/10

Hsc - Higher Secondary Certificate, High School/Secondary Certificate Programs, 69.66%

Ssc - Secondary School Certificate, Primary & Secondary Education, 69.00%