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Manufacturing Quality

Location:
Bengaluru, Karnataka, India
Posted:
August 28, 2017

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COURSE

INSTITUTION

YEAR OF

PASSING

PERCENTAGE OBTAINED

1ST YEAR

02nd Year

3RD

Year

4TH

Year ( INPLANT TRAINING)

SSLC

VALMIKI -high school- Hospet

2001

72.16%

DIPLOMA in TOOL & DIE MAKING

GOVT.TOOLROOM & TRAINING CENTER (GT&TC) - HOSPET

2005

72.40%

77.69%

77.12%

83.0%

EXECUTIVE

-MBA (Distance education)

KSOU-MYSORE

2014

64.7%

69.1%

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FIRST YEAR - Bench work exercises involving skills such as sawing, Filing, Marking, Fitting and other

Basis bench fitting operations.

-Basic and advanced machining skills on Drilling, Shaping and Turning.

SECOND YEAR

-Basic and advanced machining skills on Milling, Surface Grinding, Cylindrical Grinding, Engraving, etc.

-Auto-Cad Drawing.

THIRD YEAR

-Manufacturing of press tools like Piercing Tools, Blanking Tools, Progressive Tools, Compound Tools, etc.

-Manufacturing of Plastic Hand Injection Moulds, Two plate Moulds for automatic Injection moulding machines, etc.

-CNC-Milling and CNC-EDM Machining and Part Programming.

-On-job Training in Manufacturing of commercial Press Tools, Plastic Injection Moulds, Jigs and Fixtures.

FOURTH YEAR ( INPLANT-TRAINING) - From 12th july-2004 to 04th july-2005

-Undergone inplant training at MGM- Industries, Mysore,Karnataka state for one year.

During inplant traning I have done forging dies using CNC-milling and EDM machines.

Successfully completed the project of Rotar claw part designing and manufacturing by own initiative and developed customer part independently.

Learnt the complete process of manufacturing forging dies and trimming tools.

Learnt Delcam software for easy programming for cnc milling.

Got complete knowledge of cnc milling and edm machines.

Developped gauges and fixtures for easy machining and speed up the process.

- From 21st November-2005 to 31st August-2011

Worked as Assistant Techinician for 5years 9months to the Tool Room Department at TRACTORS & FARM EQUIPEMENT LTD, Engineering Plastics Division,Doddaballapur, Bangalore, Karnataka State.

During 6months of professionarry, I have proven myself by achieving well operating of CNC milling,

Edm machines, gun drilling machine and die spotting machine.

Done well supervising of followers and achieved defect free manufacturing of large and medium moulds.

Planning of complete mould manufacturing process.

Estimate all process time and manufacture according to timeline.

Achieved department targets like OEE 85%, Ontime delivery,

Support to the assembly of moulds with new ideas and techniques.

Problem solving of tools in assembly as well as solving defects in parts being moulded.

Expertice in handling manpower of 35 members and continueos training to all workers.

Motivate sub-ordinates and well trained of effective utilization of manpower and machines.

Developed many quality checking methods of mould making.

Planning of gauges & fixtures for moulds manufacturing as well as inspection.

Well knowledge of moulds making and assembling.

Co-ordinating design to the manufacture of moulds simple and easy concepts.

Succesfully completion of TOYOTA INNOVA CAR PROJECT consists of 12 parts developement.

Succesfully completion of development for TVS-SCOOTY COMPONENTS totally 6 nrs of tools,TVS-SCOOTY PEP 16 NO OF TOOLS, TVS-SCOOTY STREAK 18 NO OF TOOLS.

Successfully errection, installation of new machines in lager size tool manufacturing plant

Succesfully completion of NISSAN CAR PROJECT all 10 tools of larger moulds

Successfully implemented 5S in shop floor.

Succesfully completion of EXIDE JAR mould component length was 0.6 meter in machining.

Succesfully completed a deep cavity machining depth 600mm depth in HMC type machine.

Achieving the machine overall equipments effectiveness AVG 85% in a month.

No Non- confirming reports (NCR’S) received so far during survialence audit conducted by TUV.

Succesfully completed the SPEAKER GRILL TOOL in sparking process.This one would do in JAPAN.

Succesfully completion of RADIATOR component (automobile parts) TOOLS for TATA-TOYO Company.

Part of Success team in achieving customer delight.

Key member in implementation of TPM & KEIZEN’s.

- From 12th September-2011 to 12th October-2016

Worked as a Group Leader for 5years 1month in Tool Room Department at

INDO-US-MIMTEC.PVT.LTD. Doddaballapur, Bangalore, Karnataka state.

For the first 2 years I worked as specialist R&D for tool room and set-right all internal manufacturing processes like Design Reviewing, Electrodes designing & Electrodes setting, Soft machining, Heat treatment, ElectrodesMilling,Hard Part milling,Edm,Wedm,Surface-Griding,Cylindrical Grinding, Inspection methods, polishing methods etc.

Developed a strategic vendor management techniques and developped vendor skills according to our needs in material supply and mouldbases machining.

Developed Standard elements ordering and store management.

Developed Standard Operating procedures for all tool room processes.

Done well supervising of followers and achieved defect free manufacturing of Medium and Baby moulds.

Developped FMEA in the department.

Set-right the quality achieving methods in all processes with in 10 microns.

And the next 3 years I have taken complete Tool room activities lead and Heading Tool room- PPC

( process planning and controlling) and Reporting to Department general Manager.

Through tool room PPC- I was Planning and scheduling of complete moulds manufacturing processes, giving daily targets for all process owners and ensuring plan/actual on daily basis

Communicating delivery dates to the internal customers and satisfy customers through ontime delivery and quality.

Co-odinating design department and releasing designs for manufacturing.

Estimate all process time and manufacture according to timeline.

Achieved department targets like OEE 90%, Ontime delivery,

Support to the assembly of moulds with new ideas and techniques.

Problem solving of tools in assembly as well as solving defects in parts being moulded.

Expertice in handling manpower of 45 members and continueos training to all workers.

Motivate sub-ordinates and well trained of effective utilization of manpower and machines.

Developed many quality checking methods of mould making.

Planning of gauges & fixtures for moulds manufacturing as well as inspection.

Co-ordinating design to the manufacture of moulds simple and easy concepts.

Leading Cost saving and Cost reduction activities.

Taking Lead of Manufacturing lead time reduction.

Taking lead of Moulds assembly/week and month

Taking lead of quality and ontime delivery of moulds.

Taking lead of solving issues during and after trials.

Leading TPM, Kaizen,5s development activities in the department.

Repairing of moulds to get maximum tool life.

Developed good practices of Moulds maintenance.

Succesfully done the installation of brand new machines.

Achived department objectives, 90%OEE, achieving Right first with quality controlling methods,

Rejection controlling from 30% to 5%.

Machines Down time reduction from 35% to 10%.

Mould making lead time reduction from 45 days to 28days.

Implementation of Inventory management in the department.

Made Manual Automatic Tool Changer (ATC) for all 20 Cnc-edm machines,which is saved approximate Rupees 2crores where it was costing Rs.12 lacks/machine. We developed with available resources with in Rs.2 lacks/machine.

Developped methods of Re-use of copper and Graphite electrode materials till the maximum usege, which it’s saving Rs.60,000/month.

Reduced the manpower in Cnc-milling by setting multi job milling in single set up time. Before it was one operator for each machine and 1 programmer for two machines, here I cut off the operator presence by setting the 4 numbers of system 3-R work holding chucks in each machines and maintained the quality by pokayoka which is helped operator can able to run 3 machines with one programmer.

Identified the cause for accuracy variations in world wide Supplier of System3-R holders and altered the holder sizes for maintining the accuracy standards.

Developed the Total output of upto 60 moulds/ month by increasing the OEE and effective manpower utilization.

Succesfully installed and setup the profile grindning process for accurate parting surafaces of mould, which it helps in maintaining accurate profiled mating parts and for better tool life.

Developped a critical and complex medical surgery Parts like Hub, ear holder, troma plate etc.

Succesfull developped a critical component of Mobile charger socked for Apple mobiles through metal injection moulding method.

Developed critical Automobile, automotive and medical components with lean manufacturing practices.

Set right the complete process flow with best practices of mould making activities, which helped to improve in profit for the organisation.

Helped to organisation Awarding from customers as a World class toolroom in india with class improvement in 5s, Tpm and developping appearance of the department.

Achiving of ontime delivery (two days delay maximum) of tools according to the plan.

Developed proto type mould making with in 24 hours.

Developed flash correction team of 8 toolmakers of 15-20 tools a month.

Developed centralized route cards for all processes to better flow of process.

Develepod pre-assembly method to reduce the final assmbly hours of mould and achieved final tool assembly in 2 hous max.

CEO

Vice president

Department General Manager

Toolroom group leader-PPC

Section incharges (milling, edm, wedm, grinding, inspection, assembly.)

All 3-Shift supervisors of each section.

Operators

Trainees

Proficiency in machining proceses like drilling, reaming, boring, turning, cnc-milling & special process, cnc- Edm.

Proficiency in problem solving tool like WHY-WHY ANALYSIS.

Proficiency in Deep hole drilling operations.

Proficiency in doing angular operations for angular ejectors.

Proficiency in good manpower controlling,directing,training.

Proficiency in On-time completion of Projects.

Proficiency in tool assembling, AUTOCAD & PRO-E-Design-Techniques.

Proficiency in estimation of both sparking & machining processes duration time.

Proficiency in good LEADERSHIP

Proficiency in ISO /TS 16949:2002 & ISO 14001: 2004

OEE-management

TPM-management

FMEA-implementation

Excellent Communication Skills.

Leading CFT team

Changing design concepts according to available manufacturing resources.

Inhouse Trainer for both QMS & EMS

Standardization & simplification of the process

Implementing Quality Systems in Shop floor for sustainance growth

Conducting Why-Why Analysis,

Team Building & Management

Good Knowledge on ISO 14001, TS 16949.

Good zeal in learning new things and Ready to take up Challenges.

Hands on experience of taking quality input, ensuring quality in process and quality output.

Hands on experience of problem sloving of moulds assembly.

Achieving technical competencies of all sub-oridinates thorugh motivation and training.

Achieving department targets and goals.

Windows 2003/XP, MS – Office-2003

Auto CAD 2003

PRO-E- electrodes designing and mould making ideas.

Delcam

MS-access & power point presentation

1. Mr.Ganesh.R

IT-Analyst

TCS- Bangalore

Ph; 963*******

2. Mr.Kotresh

Tool room engineer

Indo-mimtech.pvt.ltd

Ph-959*******

DATE: -19-8-2017

PLACE: - Bangalore SHRAVANA KUMARA.R



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