• Report to Operations Director; Leading the Welding, Assembly and Packing unit and lead 110 -member team including 3 direct reports and 8 Indirect reports. • Accountable for production planning, gross margin targets, cost control and optimization, budgeting, strategic planning, production, quality, WIP inventory management, process improvements, new product development Line related and customer Complaints.• Responsible for handling on daily / weekly / Monthly review meetings with the Safety, Quality, Maintenance, Planning, Warehouse, Continues Improvement and Tooling department.• Conduct comprehensive training sessions and workshops on various DBS topics, including Value Stream Mapping, 5S, Kanban, FMS, Andon system, SMED, and Kaizen, to enhance team capabilities and operational knowledge.• Lead, train, and coach a team of production staff, ensuring performance and motivation. Conduct regular performance reviews and provide constructive feedback to team members.• Collaborate with the maintenance team to ensure that production equipment is well-maintained and operating at optimal levels.• Responsible for all the departmental audits like ISO, QMS, EHS etc.• Experienced in environmental, health, and safety reporting, ensuring timely safety audits, and adhering to ISO 14001 & ISO 45001 standards. Responsible for safety incident investigations and corrective actionsHighlights:• Distinctively reduced the process scrap from 1.2 % to 0.58 % & reduced customer end rejections to 80 PPM.• Improved Productivity in Flanging Machine from 1100 nos. /Shift to 1400 nos. /Shift by optimize the Travel distance and Reduced the Motion of the associates.• OEE of the critical machine improved from 67 % to 79%• Achieved cost saving of Rs.16 Lakhs in 12 months’ span of time through various cost reduction projects• Reduced changeover time from 30 minutes to 15 minutes by implementing the SMED concept, leading to increased production flexibility and responsiveness.

Utilize inputs from Manufacturing Engineering, Tool Design and Manufacturing personnel to develop technical proposals. Experience in Working closely with Cross Functional Team (Application / Engineering, Procurement, Project management, Manufacturing, Maintenance and Quality) during all phases of product development to optimize process designs for SPQCDM (safety, productivity, quality, cost, delivery / efficiency and maintainability / reliability). Develop time study analysis to establish optimum cycle time, work sequence, Layout and production capacity for each process step. Identify potential bottlenecks in production and propose improvements to minimize lead time and maximize productivity. Build in Poka yokes in the process and ensure zero defect process. Interact with quality and production team to ensure no deviations are done by the operators. Validate process periodically. Familiar in utilizing the core tools including MSA, SPC, FMEA, APQP, PPAP and Control plan. Establishing process control charts, monitoring Poka-Yokes in in-process and prepare standard operating procedures.Highlights:• Received Best Launch award for BSVI Project from the Global Top Management Team.• Commissioning and Installation of 4 Robot welding Machines, 3 Leak testing Machines ,15 Manual welding Station, 3 Assembly stations,1 laser welding and cutting Machine, and 15 Checking fixtures with in the period of 12 Months.• LV Exhaust Production Ramp up from 15 Numbers to 200 Number per shift by Using lean tools • CV Exhaust Production Ramp up from 5 Numbers to 50 Numbers per shift by Using Lean tools.• Overall plant productivity improved from 69.4% to 83.5% by use of Lean tools.

Calculation of Manpower Requirement and initiate improvementsEnsure MTM studies for Series projects and maintain SAP Routings up to date.Prepare and coordinate Business case presentations based on requirement of Plant Manager,Responsible for coordinating Continuous Improvement Process (CIP) within OperationsPlant Capacity analysis and improvement.

Robot System - MotomanKnowledge of Programming, Set Up & maintenance of robotic Welding System.Develop Welding Programs based on technical drawings.Robot simulations to validate and optimize welding paths, cycle times, and efficiencyknowledge of welding techniques (MIG, TIG) and metal fabrication processes.

TIG Robot welding Programming, Production Monitoring

Operate robotic welding machines to perform various welding operations.Program and set up robots for specific welding tasks using programming languages such as MIG, TIG, etc.Ensure high-quality welds by monitoring and adjusting machine settings, parameters, and processes.Troubleshoot issues with robotic welding machines and resolve problems efficiently.Collaborate with team members to optimize production workflow and improve overall efficiency.

CNC Program Codes Teach to studentsCNC Machine setting Parameter Explain to studentsVMC and Turning Codes difference teach to studentsRegistration Administration Certification issue to once course completion

Setup CNC based machinesWriting code for VMC/Turning Job Setup and ProductionAchieve production target and machine OEE.Improvement of productivity consistencyDe-bottleneckingReduce rejection RatesAccuracy and Reliability