Production and Productivity improvement through Lean.

COO, Vehicle Division

Implementation of TPM and improvements in forging.

I worked as GM Operational Excellence, responsible for plants at Pune (3 units), Bangalore, Halol and Coburg-Germany. My job was to inculcate operational excellence in plants through improving - processes, production, productivity and reducing – wastages, cost using Lean Six Sigma. I used operational excellence to improve processes, did line balancing exercises, work measurement, improved incentive schemes that improved production and productivity by 5%. . My salient… Show more I worked as GM Operational Excellence, responsible for plants at Pune (3 units), Bangalore, Halol and Coburg-Germany. My job was to inculcate operational excellence in plants through improving - processes, production, productivity and reducing – wastages, cost using Lean Six Sigma. I used operational excellence to improve processes, did line balancing exercises, work measurement, improved incentive schemes that improved production and productivity by 5%. . My salient achievements are as follows:Initiated Lean Six Sigma awareness among employees through imparting training and conducting workshops. More than 50 persons have been trained as Green Belt and implemented 9 projects with savings of Rs 20 million.Improved labor productivity in TACO Kunststofftechnik GmbH in Germany by improving working methodologies using work study and Lean. This resulted in annual savings of 0.5 million Euro. Show less

I Worked as Chief Manager (IE&QA). I was responsible for the improvements in processes using Lean for profitability in units at Faridabad, Noida, Chennai and Mumbai. Thomson press is Flagship Company of India Today Group and South East Asia’s largest integrated printing press. Press has four plants at Faridabad, Noida, Chennai and Mumbai. I was in Faridabad plant which is also the corporate office. I was responsible for Industrial Engineering of Pre press, Web, Finishing… Show more I Worked as Chief Manager (IE&QA). I was responsible for the improvements in processes using Lean for profitability in units at Faridabad, Noida, Chennai and Mumbai. Thomson press is Flagship Company of India Today Group and South East Asia’s largest integrated printing press. Press has four plants at Faridabad, Noida, Chennai and Mumbai. I was in Faridabad plant which is also the corporate office. I was responsible for Industrial Engineering of Pre press, Web, Finishing operations, Sheet fed, Hard case and Dispatches. This plant has a turn over of over Rs 2500 million. My salient achievements are as follows:a. Reduced the machine down time from 7% to 4%. The plant efficiencies improved by 5%. Productivity improved by 5%. Wastages reduced by over Rs. 10 million. All this achieved through applying IE techniques. b. Improved cycle time of finishing operation by 22% thus helped dispatch the magazines 8 hrs before scheduled time helping the organization in getting the magazine in the market much before the competitor’s magazine arrived. Show less

Worked as manager improvement implementing Lean Six Sigma, Value Engg. and Industrial Engg practices. Also implemented Total Operational Performance with the help of Mckensey Consultant.

I worked as Industrial Engineer in the Foundry, Forge, Axle, Engine and Assembly Divisions as well as in Tata - Hitachi Excavator Division. My salient achievements are as follows:- My contribution was in preparing time standards for jobs in Foundry, Forge, Engine, Axle, Assembly and Excavator Divisions. -Studied indirect manpower of Production Control Dept. and reduced it by 30%.