Pavan Kumar A Email & Phone Number

Bengaluru, Ka, In

Bengaluru, Karnataka, India

India

• Underwent extensive training in Japan, gaining in-depth knowledge across various manufacturing sectors. Observed and learned efficient line management, Kaizen improvements to enhance shop floor efficiency, and best practices for maintaining safety and quality standards.• Achieved TICO (Toyota Industry Corporation-Japan) President Award for designing and manufacturing the best sub-assembly line as a DIY project, achieving cost savings of ₹6.7 million annually in 2 months.• Awarded Best QCC Advisor for optimizing raw material feeding, reducing man movement by 40% (from 5 km/shift to 3 km/shift), improving Ergo score by 26%, and decreasing cycle time by 24%.• Saved ₹66,000 with bin optimization and DIY solutions, reducing trolley parking by 3 sq meters and halving trolley usage.• Enhanced FG loading skid, increasing container efficiency from 32% to 76% and saving ₹4 lakh by reducing container needs from five to three 40-foot containers.• Cut lead time for sub-assembly parts to the main line from 8 shifts to 1.25 shifts (84% reduction)• Elevated production capacity from 4.5 shifts to 3 shifts,• Reduced line rejections in assembly line-1 by 96% (from 325 to 13 parts/year) and in line-2 by 21% (from 107 to 84 parts/year)• Lowered quality complaints by 94% in assembly line-1 and 34% in line-2.• Optimized MHE usage from 120 min/machine to 5 min/machine (96% reduction).• Boosted production capacity by 33%, increasing output from 25 to 35 Units.

Bengaluru, Karnataka, India

• Management of Multiple Assembly Lines: Led and managed 3 Assembly line and a Packing line with 50+ Associates ensuring the efficient flow of production and timely delivery of output.• Sustainability & Standards Implementation: Played a key role in setting up sustainable practices and establishing standard operating procedures (SOPs) in line with the company’s Hoshin planning, aimed at optimizing resources and reducing waste.• Production Planning & Backlog Management: Worked closely with senior management to develop production strategies to address backlogs, ensuring alignment with company goals and reducing lead times.• Manpower & Shift Management: Coordinated manpower allocation and shift schedules to meet production demands, optimize labor efficiency, and ensure minimal downtime across all lines.• Process Improvement & Lean Manufacturing: Continuously monitored assembly & Packing line performance, implementing process improvements and lean manufacturing techniques to enhance productivity, reduce errors, and maintain high product quality.• Cross-functional Collaboration: Collaborated with quality, maintenance, and supply chain teams to ensure smooth production operations and address any challenges that arose on the shop floor.

Bengaluru, Karnataka, India

• Project Management - Sub-Assembly Line Setup: Led a team to design, develop, and implement a custom-built sub-assembly line through a DIY approach, improving the overall efficiency and flexibility of the production process.• Workstation Optimization: Spearheaded the modification of all workstations, focusing on ergonomic design to enhance worker comfort, safety, and productivity, resulting in improved workflow and reduced fatigue.• Kaizen Implementation: Led numerous Kaizen initiatives, successfully reducing quality complaints, minimizing part rejections, and streamlining production processes.• Process Innovation & Continuous Improvement: Introduced innovative process changes that significantly improved production quality and reduced downtime. Employed lean manufacturing techniques to eliminate waste and optimize production flow.• Quality Improvement: Collaborated with the quality assurance team to address recurring issues, resulting in a measurable reduction in defects and customer complaints.

Bengaluru, Karnataka, India

• Assembly Line Management: Oversaw daily operations on the assembly line, ensuring smooth workflow, timely production, and adherence to quality standards.• Process Improvement: Assisted in identifying inefficiencies in assembly processes and contributed to the implementation of lean manufacturing practices to enhance productivity.• Workforce Coordination: Coordinated with shop floor workers and supervisors to maintain production schedules and resolve operational issues.• Training & Development: Participated in the training of associates on safety protocols, machine operation, and assembly techniques to improve their performance.• Data Analysis & Reporting: Monitored key production metrics such as cycle time, downtime, and defect rates, reporting findings to management for continuous improvement.• Cross-Functional Exposure: Worked closely with other departments like procurement, quality assurance, and maintenance to ensure end-to-end efficiency.