Engineering Project

SAMEER S. BARMUKH

E-Mail: *************@*****.***

Mobile: 090********, 098********

Manufacturing Engineering/Process/Project/IED

PROFESSIONAL SYNOPSIS

A dynamic management professional with 16-17 years of rich indigenous experience in Manufacturing Engineering/ Project/IED with key focus on top line profitability as well as optimal utilization of resources in the Automobiles Industry.

Expertise in devising significant solutions, managing day to day manufacturing operations on shop floor and projects for making effective utilization of man, machine, method & materials.

Three times selected for an abroad training in Europe Portugal, Germany, as representative from Engineering department from Tata Yazaki Auto comp Ltd & FIAT-ITALY, TURKEY as Car-launching team member .

Expertise in Work Measurement Techniques -analysis & designed work content by Most, Mdat techniques as well as Wplanner & UAS Technique.

Efficient in implementing new ideas for improving production & quality through various Quality Manufacturing System.

Resourceful in making the details available for production for designing of new products with the confirmation of the feasibility as well as the ease of production & manufacturing activities.

Efficient in ensuring production and manufacturing activities as per required process, engineering drawings in the shop floor.

Adept at managing design engineering operations involving product design & development (new tool / fixtures), developing detailed drawings, co-ordination with internal department, material submittals, process developments, interfacing with customer and vendors for technical queries, technical evaluation as well as testing & validation to achieve product excellence at the lowest overall cost.

Excellent in setting up & ensuring smooth functioning of operations of large manufacturing, assembly lines & Machining line, enhancing operational efficiency by using leading edge manufacturing technologies including Business Reviews.

Excellent in defining & implementing quality standards & structured processes / internal control plans for manufacturing operations of equipment and machines as well as standard products ensuring accomplishment of business goals across the assigned business units.

An effective communicator with excellent relationship, team building & building & interpersonal skills. Strong analytical, problem solving & multitasking abilities. Possess a flexible & detail oriented attitude.

KEY SKILLS

Certified World class manufacturing ( WCM) & Train the trainer

Six sigma-MNAL Yellow belt

Strategic Planning

New Process Establishments

Budgeting & Cost Control

Process / Product Enhancements

Process Validations & Process Auditing

DCP,FMEA Implementation

Work measurement -MOST Techniques, MDAT software, UAS, W-planner

Lean management, Line balancing

Project Management

Resource Optimization

Manufacturing Quality

ORGANIZATIONAL EXPERIENCE

Mahindra Vehicles Manufacturing Ltd-Chakan-Pune Since JULY 2010

Deputy Manager (CME/Project Management- Mahindra Navistar Commercial Vehicle Project)

Key Deliverables

Responsible for designed work content by MOST techniques and calculating work content in MDAT Software Cargo/Cowl variants MN31,MN25,25 T Std Tipper, Long wheel base Truck MN25T 6100 LWB, MN25 T 6600 LWB,31T LWB 6600,Cowl variant,40T Tractor AC/ABS,35T Tractor Mechanical /Electronic.

Process planning, Stage wise layout and Making DCP documents-Process flow chart, Process FMEA, SOP, Process sheet for all variants Trim line-Cabin 1S-2S, Cowl, Day Cabin.

Line balancing of Production line Chassis, Final, and Trim, Engine as well as Axle line.

Capacity planning & enhancement project for 5 JPH (2 shift basis) as well as 9 JPH (1 shift basis) in Trim line.

FTG planning, Poka Yoke, Templates, Tools & Consumable replenishment for Trim line.

Machine Capability study, SPC study of Windshield Robot application of trim line.

Updating of MHCV Assembly process 2D Autocad layer layout for new variants of facilities, tools, equipments & Logistics planning.

Active CFT member of QCRT team & NVA elimination team & Ergonomics concern-Motion study, Therbligs –concern solving concern.

Process audits with Quality experts from MNAL and demerit point closure through process establishment on Production Line.

Work analysis with MDAT Method and actual Process Shooting to fix out HPV for production line and manpower allotment to concerned area as per JPH, TAKT TIME.

Delivering BHAG-Leveraging rise principle through initiative in Productivity, Quality and Cost.

Identifying NVA and eliminating them by taking process change projects.

Highlights

Successful in establishing 11 models within a short span of time in Trim line all considered process aspects as well as following all MNAL norms.

Played a vital role in NOVA C, Fault Tracking as well as clearing all defects within 2 weeks spans which enabled early process establishment of Trim line.

Undertook work analysis of calculating the designed Work content by MOST/MDAT techniques and Line balancing efficiency 88% for product mix variety of 11 Different commercial products within 6 months.

Fiat India Automobile Pvt. Ltd, Ranjangaon, Pune April 07 till June’10

Deputy Manger (Centre Technology & Project Management)

Key Deliverables-Central technology/Project

Successfully executed the following Green field projects: LINEA, Grande Punto and TATA Indigo Manza.

Responsible for Power and free Conveyor Completion line (PF 2,3,4 line ) assembly set up planning, procurement and commissioning .

Prepared stage layout for the fitment Exhaust pipe, Steering, Hand brake, AC fitment assly, Cabin Interior, Tyre and seat assembly, Front Bumper, Rear Bumper fitment, Fog lamp, Head lamp, rear lamp fitment, and Filling machine (Power steering, Brake oil filling, Radiator Coolant filling, Brake oil filling ABS /Non ABS.) considering operation involved, material / man movement & throughput time.

Successful planning and procurement of assembly equipments for completion line.

a.Head lamp aiming and Fog lamp setting cum sub assembly fixture

b.RFQ, Commissioning of Radiator Coolant, AC filling, Power steering oil, Brake oil filling machine- ABS-Genix make.

c.Seat and Tyre Overhead conveyor assembly line.

Installation and proving of PF line set up for cycle time

a.Continuous improvement in the PF completion line set up by understanding the various upcoming problems while 10 min to 4.5 Min Takt time line and resolve them by providing the fixtures, templates, adding new tools so as to reduce the operator fatigue and achieve the cycle time.

Cycle time reduction by change in process & improving manufacturing setup.

Process FMEA studies for PF seat and brake oil filling machine.

Introduced PDCA cycle & POKA YOKE to reduce the errors and improve the productivity.

Resolved the field issues and internal quality issues.

Capital Equipment planning, Purchase & Commissioning.

Battery, Driver, Co –Driver seat, Spare wheel local make manipulators & Nut runner reaction system.

Procurement of consumables like small bits & sockets for the assembly line.

Other Highlights

Major projects handled:

-Fiat Linea, Fiat Punto, Tata Manza.

Measures to enhance employee performances / career advancements:

-3 Models established with team work in 1 year period.

Achieved a smooth process set up, thereby enhancing the production activities effectively. – Process Technology

Gained experience at Car Manufacturing from plant building stage till the actual product / process establishment up to the product launching stage. – Assembly.

John Deere Equipment Ltd, Sansawadi,Pune Jan’06 till March’07

Process Engineer

Key Deliverables

Asst. Manager (Manufacturing Engineering/IED-Vehicle assembly)

John Deere Equipment Ltd-USA MNC is a world’s first largest Farm vehicles Tractor industry, supplying engines as well transmission all over world with 750 cr. turnover etc. to Domestic as well as Overseas. The plant consists of in-house Engine, transmission as well Vehicle manufacturing plants at Pune. Company is QS-9000, ISO-14001.

Roles & responsibilities:

Responsible for New Project estimation and planning & execution-Krish tractor expansion vehicle assembly manufacturing line future launch project 2008.

Implemented MTS, PMTS work measurement W-planner, Line balancing of production line & Simulation inventory for Vehicle assembly-overhead conveyor line.

Design & Procurement of material handling devices, logistics support as well Low cost automation small projects for productivity improvement.

In team Implementing Deere Production System and Lean Mfg-Value stream Mapping, JIT, and KANBAN.

Co-ordination for SOP as well as Continuous improvement Process (CIP) implementation.

Calculation of Overall equipment efficiency (OEE), Line Balancing & Plant Capacity.

Preparation of Plant Layout by Factory cad layout, initiating 3D layout assembly.

Co-ordination with External suppliers, vendors for Fabrication & new development.

Achievements:

Execution of proper line balancing, optimization labor & simulation increased 65 tractors to 90 tractors per shifts with existing manpower.

Designed, implemented devices in Paint shop as well as in assembly area handling device-manipulators to better loading–unloading hood with time saving as well as reduced 6 Operators/shift.

Adding in bottleneck sub-assembly stations so that line capacity increase.

Handling new product & creating PI (full form) for cell members.

Resolving process related FPY problems with innovative techniques.

Extending Online Yield Control in process view as well as killing the root cause, capable of harming the yield.

Bharat Forge Ltd, Chakan-Mundhwa Pune. March ’04 till Jan ’06

Manager (IED/Project-MCD division)

Key Deliverables

Increase Productivity on Vista Crankshaft machining line cycle time- tact time 10min improved to 6 min. by Process modification( Speed, feed & Tooling Improvement).

Responsible for Low Cost Automation, Motion study,Material handling devices improvement.

Implementing Toyota Production System and Lean Mfg-Value Mapping, JIT, KANBAN, Single Piece flow.

Take Time and motion study and prepare Man-Machine Combinations & Work standards, Setting Standard time.

Implemented Basic MOST in Toyota Line, BPR concept. Calculation of Overall equipment efficiency (OEE), Line Balancing, Plant Capacity.

Preparation of Plant Layout, Process Layout by CRAFT as well as Template methods, Implementing Cost Reduction & Rejection Reduction.

Achievements:

Designed Number punching machine for Crankshaft and Knuckle. Reduced 11-contract manpower. Designed Hopper system for centralized chip management. Improved 5S, Time saving and better control.

On Toyota line Design, Procurement, Install FIFO Racks, Finish material chutes, Raw material chutes.

Installation of Steering knuckle line, IVECO, Vista crankshaft lines as Project Team member- Engineering.

Implemented BPR-Value added mapping - One Man Multi-machine Combination - Saving of 38 technicians in two months by Video shooting, PQ analysis tool.

Designed Stage washing machine for Crankshaft., Developed One Spot Project Status system. Easy project tracking. Reduction in failure.

Highlights

Provided effective help to MPS (Mahindra Production System) People in achieving a reduction for manufacturing.

Gained knowledge about:

All logistics work in company like audit preparations, prerequisites for ISO Certification, etc.

Tata Yazaki Auto comp Ltd, Pune., July ’96 till April ’04

Associate Member (Production Engineering ).

Key Deliverables in Production Engineering

Preparation of Work Instructions, Test instructions, controls Plan, Inspection point as per quality standard.

Process analysis, Establishing, setting new production conveyor lines, Impact press & applicators in pre-assembly as well as assembly sections.

Trouble shooting of WEE Testing harness testing machines, making Program of Testing harness in WEE IVIS4/ CVS 2000 software.

Preparation of QS-9000 related documents (FMEA analysis, Ishikawa diagrams)

Procurement & Planning of spare parts of Tooling.

Conducting of 5S audits, internal audit members on Shop floor.

Achievements:

Selected abroad training for YEL Engine harness project to Yazaki Portugal, Germany to learn processes, Technology & set up new machines, trouble shooting of machinery.

Made master control database for easier, faster, accurate controlling of consumable spares parts .

Won 3 Suggestion awards for Cost reduction & time reduction for improvements in crimping tools design modifications, process layout as well as lead-time.

Selected abroad training LEONI PORTUGAL Cockpit Mercedes harness project to learn WEE S/W.

Investigating & resolving problems observed during assembly with the help of CITs (full form) & Pokayoke, FMEA.

In plant Training-

Tata Engineering & Locomotive Company Ltd., Pune. 1995-1996.

Trainee Engineer

Light & Heavy machine shop orientation program.

PE Shop

H Block Hitachi line & D Block Gear Box division

Machined component division- Unit assembly &SPM- Machine assembly section

PROFESSIONAL ENHANCEMENTS (TRAININGS ATTENDED)

World Class Manufacturing-WCM Certified ISVOR ITALY 2 months

Car Launching Team member –Online training assembly shop 1 month–TOFAS Turkey –For Linea,Grande Punto variant.

Proof technique software and WEE testing S/W training in Leoni Portugal training from TS department-1 month.

Engine harness process training in YEL Yazaki Europe Ltd-Portugal 1 month.

DCP, MQS, MPPAP, Result Orientation and Execution Excellence, Time management

Mahindra Navistar Yellow belt training

Catia 19,Factory Cad

SPC, & 7 QC Tool, Value Stream Mapping.

Toyota Production System, World Class Manufacturing, Lean management.

MOST Technique & MDAT software application, UAS, WPlanner Work measurement techniques.

IS 14000 Implementation on Shop Floor

Festo Electopnumatics EP-211 (Level-2)

German Language Course-Max Muller Bhavan Pune.

ACMA participation training -5S audit, SMED, Kaizen, Train the Training, TPS, Lean Management.

ACADEMICS

MBA in Production and Material Management pursuing IBMR college Pune University.

Graduation in Industrial Engineering from IIIE (Indian Institute of Industrial Engineering, NITIE Mumbai),2010.

4 Year Diploma (Production Engineering) from Agnel technical College Mumbai University, 1996.

CAD/CAM /CIM by COEP Pune 1996.

ADCSSA (Advance diploma in Computer software & system administration-Mumbai) 1998.

IT SKILLS

Well versed with Windows, MS Office, Internet Applications, MOST –MDAT software, Wplanner, WEE IVIS4 and Autocad 2009.

PERSONAL DETAILS

Date of Birth : November 30, 1974.

Address : A-402, Vastushree Pearl, Shikshak Nagar, Behind Utstav Hall,Kothrud, Pune -411 038.

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