As an Engineering Manager at TVS Electronics Limited, I oversee and manage a range of technical projects within the Electronics Manufacturing Services (EMS) sector. My role involves leading end-to-end project execution, from planning through to delivery, ensuring alignment with organizational goals and customer requirements.Key Responsibilities:Spearheading NPI projects to ensure smooth transitions from design to manufacturing, optimizing processes, and collaborating with cross-functional teams. Leading SMT and back-end production line setups, tool design partnerships, and process validation. Driving efficiency and data visibility through the integration of Shop Floor Control Systems. Engaging with Contract Manufacturers across product lifecycles to maintain design and quality standards. Managing Documentation Control and Engineering Change processes. Training production teams and mentoring engineers while developing cost-efficient strategies aligned with financial goalsNotable Achievements:Managed the rapid delivery of 145000 printer units within 45 days for a central government order by optimizing machine utilization and reducing cycle time.Transitioned 21 existing projects to serial production within six months through strategic planning and effective collaboration.Increased productivity sixteen fold by converting the SMT process to low-melting solder paste, automating the assembly process.Reduced costs by 1.5 million INR and recovered an additional 1.5 million INR by developing an in-house dross recovery machine.

Employment DescriptionLed the validation and qualification of solder paste and flux chemistries, collaborating with chemists and cross-functional teams to ensure formulations met stringent application requirements. Provided oversight in flux formulation, addressing oxidation, cleanliness, and wettability challenges, resulting in enhanced solder joint quality.Guided the application-specific needs for Type 7 solder paste in semiconductor projects, optimizing alloy selection and flux formulation. Designed and implemented IPC-compliant test protocols, managing analytical studies and statistical analysis (MINITAB) to support critical project decisions.Managed the development of test resources, ensuring timely and effective project delivery. Executed Design of Experiments (DOE) to optimize SMT processes, presenting findings at global forums to drive process improvements.Key Achievements:Reliability Enhancement: Validated solder paste and flux chemistries, significantly improving product reliability.Cross-Functional Collaboration: Integrated application needs into chemical development, exceeding performance expectations.Semiconductor Project Success: Optimized solder paste chemistry for a key semiconductor project.Global Technical Influence: Presented findings at global meetings, driving process adoption.

 Collaborating with customer & R&D for smooth transfer of product and to conduct PVT (product validation & testing). Ensuring & Documenting the PRD (product requirement documents) like BOM, CAD & Gerber, stencil files location drawing and troubleshooting schematics along with trouble shooting guidelines received from customer end before start building prototype. Managing 5M (man, material, machine, methods & measurement) readiness, prepare project timelines and identify all resources requirement and evaluate financials for manufacturing processes. BOM preparation and scrubbing and closely coordinating with component engineers for alternate parts and EOL management. Processing Engineering change requests (ECR’s), Engineering change orders (ECO’s) and Nonconformance reports (NCR’s). Collaborated with industrial engineering team and validate line layout and prepared LBF files to determine cycle time. Ensured customer requirement are met by preparing DFM model & conducted DFM analysis, product feasibility study & FMEA for NPI build. Conducting CFT meeting and updating FMEA and control plan, periodically or based on lesson learnt during any phase of product life cycle. Prepared stage wise internal documents like SOPs, WI, process flows Checklist, PPAP & APQP. Initiating Root cause analysis and recommend corrective actions for process issues to improve the yield during mass production.

 Support & coordinate NPI roll-out. Accountable for coordination of all activities. Provide engineering support for all activities from product development process & Assembly process. To prepare process documents such as Flow Chart, Control Plan and PFMEA (Process Failure Model Effect Analysis), to prepare Work Instructions and files of special requirement for the product, and to provide the component control information Track the production schedule and keep communication with cross function team. (such as planning,AE, production & QA etc.) Analyzing and maintaining the BOM in the ERP to enable procurement of the materials. Initiating and working with CFT to perform product FMEAs and defining Control Plans. Perform continuous improvement on the product with respect to yield and cost. Successfully implement any engineering changes on the product during its life cycle. Collaborating with customers and program management to address the gaps and clarifications to meet the product requirements. Optimize and maintain the yield, cost of the product throughout the product life cycle. Providing adequate training to operators and personnel in related functions. To receive CR or other requests from customer, to review the current situation of production, and to prepare plant internal ECO.

Employment Description:Results-driven professional with extensive expertise in SMT and backend processes. Proven track record in preventive, predictive, and breakdown maintenance of SMT and Automated Test Equipment (ATE). Skilled in optimizing equipment utilization to enhance productivity without compromising quality. Adept at working independently and as a team player, effectively communicating with all organizational levels.Key Achievements:Enhanced Productivity: Successfully increased equipment productivity through optimized utilization strategies.Maintenance Excellence: Expertly managed preventive and predictive maintenance, ensuring minimal downtime and operational efficiency.Project Leadership: Led the implementation of a traceability and shopfloor control system for Vallor (Mentor Graphics), collaborating with vendors and stakeholders. Managed infrastructure modifications, line adjustments, and hardware sourcing, completing the project within a critical 4-month timeframe.

 Programming and optimization of Paste printer Pick &place, Fuji flexa, line balancing and optimization. DEK paste printer programming and process validation. Reflow profiling and validation. AOI programming and process validation. SMT related automated machines (NXT pick & place, DEK printer, Agilent AOI & ERSA reflow) trouble shooting and repair. Led the efforts in smooth maintenance and production while leading a team of shift technicians. Ensured availability of spare parts while avoiding excess inventory. Responsible for installation and reconfiguration of lines as per layouts and line balancing. Implemented various quality initiatives like Cpk, kaizen and 5S. Deftly resolved all technical issues to ensure minimum downtime.