Dheeraj Kumar Email & Phone Number

India

Providing consultancy services to a range of industries, focusing on manufacturing optimization, plant setup, and quality systems implementation. GAP Analysis: Identified critical operational gaps in various manufacturing processes, leading to optimized workflows and improved profitability. Business Development: Added new business lines and expanded market presence for clients by leveraging expertise in product development and reverse engineering. Plant Layout & Setup: Designed new plant layouts and set up manufacturing units with a focus on efficiency, productivity, and obtaining government approvals. Quality Management: Implemented ISO and IATF 16949 standards and guided companies through SQ certifications, ASSES, and IMARQ audits. Process Innovations: Introduced over 300 poka yokes and other innovations to improve safety, reduce errors, and enhance operational efficiency. Training & Development: Conducted numerous training programs on 3C, 5S, Poka-Yoke, SMED, OEE, and TPM, helping teams improve productivity and adopt best practices.Companies Consulted:1. Prominent Manufacturing – Sheet Metal Fabrication2. Ind Tech Industries – Packaging Injection Molding3. Enniox Technologies – Manufacturing as a Service4. Radiant Electroplaters – Electroplating5. Marvel Industries – Automotive Injection Molding6. Vinayaga Engineering Works – Sheet Metal Fabrication7. SKI Manufacturing – Sheet Metal Fabrication8. SKI Precision – Precision Machining9. Intercept Design – Reverse Engineering & New Product Development10. Sri Vigneshwara Engineering Works – Automotive Injection Molding11. Reuter Innovative Closures – Fuel Lid System12. Weld Tech – Setup Robotic Welding Plant13. Vaishnavi Engineers – Sheet Metal Fabrication14. New Factory Setup – Automotive Washer Bottle Assembly

Chennai, Tamil Nadu, India

Led plant operations, consistently maintaining customer PPM below 20. Introduced supplier debit system to improve incoming quality and reduce rejection rates. Successfully implemented CLUSTER meetings and reduced manpower through process optimization. Ensured plant compliance with 5S, FIFO, and KANBAN practices, enhancing operational efficiency. Actively participated in audits and score upgradation for IATF 16949, 5 STAR, and TPS standards.

India

Managed operations for a 700 Cr multinational manufacturing body parts for HMIL. Introduced process innovations including soft bushes for damage prevention and a tilting jig for quality improvement. Implemented TPM and lean practices, leading to improved Overall Equipment Effectiveness (OEE). Set up new production lines and managed critical projects in collaboration with Hyundai.

Maharashtra, India

Spearheaded plant layout preparation and automation setup for load body welding. Led the Tipper Assembly project for Ashok Leyland, improving productivity by 40%. Implemented process improvements that led to a reduction in shift operations from three to two.

India

Achieved significant cost savings by managing civil contracts and structural work in-house. Secured business for PA and TB/F/L models for Hyundai seat frames, playing a key role in supplier and project management. Oversaw recruitment, quality system development, and plant setup for a 50 Cr project.

India

Successfully led plant operations, achieving an EBIT of 10% in the first year. Awarded Best Plant for Business Best Practices. Managed the installation and commissioning of Fanuc Robots within stipulated timelines.

India

Managed welding operations for body and chassis components for Hyundai, introducing advanced welding techniques and automation. Developed shop floor layouts, coordinated team training, and ensured compliance with TPM and quality systems.

India

Trained operators and optimized processes to reduce material consumption and improve quality. Achieved multiple awards for quality and process improvements in body shop operations.

India

Trained operators in advanced welding techniques, ramping up production capacity from 4 to 32 containers per shift. Led significant improvements in welding quality and process efficiency.