Injection Molding Manufacturing

MUKUND KAMDAR 609-***-****

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Multidisciplinary engineering manufacturing technologist I understand the passion and drive it takes for you to turn lines on a page into a life-changing product. I am engineer and industrial manufacturing technologist, too and my business is building the new concept, innovative products, tooling, other components and systems that help bring your brilliance to life. I may just be a small part of your big idea, but together we can build the innovative products of the future, today. Education: B.S., M.E. and MME, VJTI, Bombay University, Maharashtra, India Computer Skills: Proficient in Office Automation:- Software: MS Office, Word, Excel, power point, CorelDraw, Photoshop, Paint, Internet/outlook Systems: DOS, vista, Windows XP

Hands on Experience and Knowledge of:

MES (manufacturing execution system), PLM (product lifecycle management), MDM (master data management), TLM (teaching/learning materials), PDM (product data management), Digital factory, EBOM(engineering bill of materials), MBOM (manufacturing bill of materials), SAP (System Applications Products), ERP (Enterprise resource planning), LIMS (laboratory information management system), SCADA

(Supervisory Control and Data Acquisition)

WORK EXPERIENCE:

Senior Consultant for Manufacturing Domain: 02/2017- Present Company: Wipro Technologies – Client: TE Connectivity, Middletown, PA 17057. Manufacturing Execution System, developing strong client relationships and managing large engagements

(single/multiple). Developing and selling innovative value propositions within the product/practice space and drive real, measurable value for clients and for developing major accounts in consultation with Consulting Partners and Sales Teams.

Providing missing link between practical floor production activities to automation (Bridge building) which will help to software development team to create new application and attributes and explore new possibilities for end use cases

Providing knowledge in manufacturing management process areas like production management, quality Management, inventory management, maintenance management and environment, health & safety

(EHS) management

Complete analysis right from beginning process till finish products

Analyze products, tooling, mold, die, jig fixtures manufacturing and maintenance, polymer, injection molding machine, mold, heating and cooling system, various kind of precision sheet metal stamping and cutting components process, secondary process like deburring, ultrasonic welding on plastic to plastic, plastic to metal, multicolored pad printing, heat treatment, plating, anodizing, polishing, final assembly, testing, packing, storage and dispatching process

Manufacturing value chain processes, industry trends and enabling technologies

Pilot in manufacturing quality initiatives including supplier quality

Analysis Cost of Quality

Productivity improvement, operation efficiency improvement projects for a manufacturing plant

Understanding of Enterprise technologies like MES, PLM, SAP and ERP, EBOM etc.

Project Management of Manufacturing Industry and Business Process Consulting Spectra Connectors, Inc., Camden, NJ. 01/2014–01/2017 Operations, Cost, Quality & Reliability Management Consultant:

Ensuring use of reliability development processes in mechanical components / sub-systems as well as all interior components used on system programs.

Reliability processes - developing function base performance standards for components & systems, DFSS

(Design for Six Sigma), TTF (Test-to-Failure) processing and training, system and component FMEA facilitation & reviewing, test/weibull analysis including DVP&R (Design Verification Plan & Report) reviewing, product, process and design standards review & approval, (ULP) problem solving approach for reducing warranty and identifying systemic issues, developing product & process development tools such as, PAT (Product Assurance Testing) manual, PSO (Process Sign-Off) manual, PET (Parametric Evaluation Technique) processing for robust reliability demonstration and manufacturing, gage R & R, user friendly spreadsheets for DOE (Design of Experiment) studies, etc.

Implementing reliability in design & development (Stress-Strength Analysis, FMEA, FTA, Tolerance & Worst case analysis, Reliability Modeling & Reliability Prediction. DFX (assembly, manufacturability, service) Parts & System Management.

Managing reliability testing - (Reliability Test planning, Reliability Protocol development, Sample size selection, ALT, HALT, RGT, HASS). Reliability fixtures design and development. Reliability Data Assessment.

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Developing & Execution of System Verification and Validation protocols.

Designing and process improvements to reduce costs.

Providing expertise and support in the operation of injection molding machine process, mold operation, rejection, waste saving, time saving and product assembly

Ensuring that quality limits maintain and productivity targets were hit

Set-up and adjust machines and auxiliary equipment and also performing troubleshooting on production issues within the process.

Train machine technician/operator to disassemble, clean and reassemble the loading system, tooling, molds and other necessary auxiliary equipment

Fine-tune process parameters until parts within specification and cycle times

Providing guidance for profit & loss, management to all departments and complete fulfillment including production, engineering, quality, planning, molding and metal stamping services.

Managing direct staff of 10 with responsibility for 180 employees across three shifts

Assisting in precision sheet metal components manufacturing, machine set-up, die setting, products process, plating process and assembly process

Implementing lean manufacturing system, throughout a $25 million process plant and a $30 million connector plant in 3 months

Plan. evaluation and improve the efficiency of business processes and procedures to enhance speed, quality, efficiency, and output

Track, monitor, and report project progress against the plan

Recognizing deviations from plan and develop corrective action/alternatives, and implementing the action of choice

Creating and implementing an initiative that reduce production process from four steps to two steps, and eliminated 80% of scrap from the process in 12 months

Keeping up to date on new development and technology in assigning disciplines and present on new 'Best Practice' methodologies, procedures, processes and equipment to the company in a proactive manner

Streamlining inventories by 50% and increased inventory turnover by 145% in 9 months

Improving customer delivery performance from 78% to 96% while reducing lead times by 80% in 6 months

Reducing scrap and waste by 26% through the 5s system

Accelerating plant responsiveness by reducing complex setups by 74% through value stream mapping

Leverage existing plant floor space and equipment through Lean initiatives allowing a 50% increase in actual sales in addition to reclaiming 26% of floor space for new production cells in 12 months

Improving customer delivery performance from 78% to 96% while reducing lead times by 80% in 6 months

Absolute Molding Corporation, Thorofare, NJ-08086 7/2013-12/2013 Manufacturing & Process Plant Management Consultant:

Reliability and quality support to the team of product releasing engineers and suppliers; reviewing design verification & production validation, conducting process sign-off at the supplier manufacturing locations for new product launch. Reviewing supplier documentation such as design FMEA, process DFMEA, control plans, process flow charts, error/mistake proofing techniques, gage R&R, DV/PV testing, process capability studies, etc. for the new product development/launch activities.

Supporting engineering/assembly plants for high warranty cost items using various quality techniques such as

root cause analysis, Pareto analysis, design of experiments, etc.

Providing management & consulting services to client in the areas of design, development and manufacturing of plastic products

Resolving machine and mold processing problems

Enhancing productivity, continuous improvement, cost modeling, lean manufacturing, performance metrics, project and plant layouts

Leading in design, testing, planning, and implementation of working methodology

Developing and managing a detail project plan incorporating: project team requirements, time phase budgets, manpower estimate and specific deliverables

Implementing corrective action and preventive action

Eliminating quality and delivery issues resulting in over $ 200,000 of savings in 6 months

Ensuring good manufacturing practice (GMP) compliance in manufacturing areas

Performing a make vs. buy analysis on an existing product line that result in the product line being brought in-house providing greater manufacturing flexibility and $ 450,000 in savings

Achieved 102% of production goals with 75% temporary employees in 3 months

Working with team leader to develop and implement strategic engineering goals and objectives

Communicating risks associate with technology-related investments and purchases MUKUND KAMDAR 609-***-****

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CEO, Owner, Freelancer & Managing Director

MK Group of Industries-Mumbai, India 5/1986-6/2013 Freelancer, OEM Manufacturers, Suppliers & Exporters: Expertise in manufacturing process right from concept to finish product, injection/blow/rotary molding components, precision sheet metal stamping & deep drown parts, plastic & sheet metal fabrication, structural engineering assembly & more

25+ years of extensive manufacturing experience in multidisciplinary industries and products with vision, passion, purpose, year after year successfully achieve revenue, profit and business growth objectives with rapid-change environments. With spectacular experience of highly engineering systems, which require deep understanding of critical business drivers in multiple industries and greatly successful in building relationships with customers, creditors, control of critical problem areas and delivered on customer commitments. Started at ground level, owned and operated businesses the group of companies from one to seven companies, 10 employees to over 650 employees with 'state of the art technique' in existing infrastructure and increase incredible production quality, capacity and profitability. Core Strength in Industrial Engineering Excellence:

Plant Operation & Management

Industrial Engineering

Mechanical Engineering

Manufacturing Engineering

Quality Engineering

Design Engineering

Reverse Engineering

System Engineering

Advance Engineering

Die & Sand Metal Casting

Plastic Engineering

Molding Science

Material Science

Reliability Engineer

Packaging Technology

Application Developments

Mfg. Assembly

Multicolored Pad Printing

Heat Treatment

Sand Blasting, Acid Itching

Injection Molding, Blow Molding,

Rotary Molding & Thermoforming

Precision Metal Stamping/Cutting

Tooling, Mold, Die, Jig fixtures

Plastic Fabrication

Sheet Metal Fabrication

Sheet Metal Deep Drawing

Process Engineering

Plating, Anodizing & Polishing

Powder Coating & Liquid Coating

Business Excellence:

Productivity Enhancement

Project Management

Plant Operation

Operation Management

Cost Engineering, Mfg. Assembly

Multidisciplinary Engineering

ISO 9001 Standards,

Lean Manufacturing

Revenue Enhancement

Profitability Improvement

Process Improvement

Continuous Improvement

CAPA process and root cause

investigation

Application Developments

Six Sigma

Strategic Financial Planning

Financial Management

Organizational Transformation

Bank & Creditors Relations

Executive Leadership

Workforce solutions

Customer Relations

AutoCAD, Solid EdgeST4

Multidisciplinary Industries Domain & Products Expertise:

Telecommunication

Industrial Products

Electro mechanical

Computer Peripherals

Engineered Connectors

Rail

Nuclear power

Safety & Protection

Consumer Goods, Cosmetics

Chemicals

Nylon Cable Ties & Fixtures

Toys & Games

Amusement Industry

Automotive

Electric

Electronic, PCB, Wire test Cords, Probes

Crimping Terminals (Lugs), Cable-Wire

Plastic & Precision Metal Components

Aircraft & Aerospace

Medical device & equipment, Hospital,

Healthcare, Pharmaceutical, Cosmetic

Government & Public Sectors

Office Supplies

Entertainment Equipment

Sand Casting & Die Casting

worldwide Export

Defense

Marine

Tooling, Dies & Molds Building

Instrument & Equipment

Mining

Agriculture

Textiles

Energy

Furniture, Bathroom Fixtures

Food & Beverage

Warehouse, Packing & Printing

Building & Construction

Connectors

Super specialty in various kind of injection molding & polymers process expertise:

Expertise in manufacturing plant operations

Established plant policies and procedures

Conformance to quality management systems (QMS) and standards

Ensuring training and continuous improvement process

Having unmatched knowledge, expertise and experience of wide variety of manufacturing high-tech engineering products and industrial injection molding, polymer & co-polymer plastics molding, blow molding, bakelite molding, FRP (Fiber Reinforce), SRP (Sheet Reinforce), PVC molding, rubber molding, insert molding, double molding, micro & macro molding, multi color molding (all kind of molding expertise). Blister molding, ultrasonic plastic welding and plastic fabrication and scrap grinding. Expertise in machine, molds, polymers engineering, material science, mold science, products and assembly inspection before the process, at the time of process and after the process up to the finish products. Interacting with internal departments to resolve injection-molding issues

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Interacting with internal departments to resolve injection-molding issues

Improving the tooling maintenance system that ensures all molds, dies and jig fixtures to produce the highest quality components

Oversaw the timely start-up of any new equipment or tools within the budget and time constraints.

Through continuous improvement, reducing cost requirements without sacrificing any data indicators

Through different designs, material changes and methodologies, improved by more than 70% and saved over 80 millions in a year in material cost

Performing simulations on different production systems to identify bottlenecks

(APQP) Advance product quality planning

(CAE) Analysis computer-aided engineering

(DDP & P) Design and development of products and processes

(FMEA/DFMEA) Failure mode effects analysis & design failure mode and effect analysis

(GD&T) Geometric dimensioning and tolerance

(PPAP) Production part approval process

(SPC) Statistical process control

(CPD) Current product development

(QFD) Quality function deployment lean manufacturing, Six Sigma, AutoCAD, & Solid edge ST4

Conducting employee performance reviews

Developing process to assure attainment of production goals

Directing and coordinate plant operations, maintaining safety standard throughout operations

Establishing and maintaining a positive culture for employees, foster a well-trained and motivated staff

Working on daily production and manufacturing operation

Reduce scrap by over 1 million dollars in a one year

Standardizing maintenance practices to improve reliability and repeatability of equipment

Spectacular working knowledge of scientific molding methods including in-mold intelligence (Such as cavity pressure, process parameter control)

Managing MK Group of Industries including seven companies, 4 locations, 2 shifts, 17 manufacturing facilities and over 650 workers

Exceptional understanding and passion for injection molding, blow molding, rotary molding & thermoforming machine process on a daily basis

Manufacturing industrial molded components for equipment for OEM clients

Expertise in machine, molds, raw material, products and assembly inspection before the process, at the time of process and after process up to the finish products

Leading LEAN manufacturing system development and implementation for various production systems LEAN improve profitability by over 12% daily inventory

Cost reduction of more than 3 million space savings of over 5,200 Sq. feet and labor cost saved more than 1 million in one project alone

Reducing manufacturing complexity and improving production capability of material

Bench marked best practice and process

Oversee a product lines and being responsible for development of new products to increase sales.

Providing support for Sales, presentations and finding solutions for new products during field visits

Presentation skills and interaction with industry and government committee’s and deal with many personalities

I am the main point of contact for clients, vendors and having hands on approach

Management experience with product development and product design.

Developing and maintaining work standards for different manufacturing systems including variety of injection molding, blow molding, rotary molding and thermoforming production & plastic fabrication

Thermoplastic, engineered and thermosetting resins/plastics processing, additives for polymer materials, advance injection/blow molding, polymer processing, plastic mold design, components and product design

Providing direction, planning, coordinating and monitoring molding operations on all shifts

Manufacturing high-tech engineering products using injection molding, polymer & co-polymer plastics, blow molding, rotary molding, thermoforming, sheet reinforce molding (SRP molding), fiber reinforce molding (FRP molding), rubber molding, bakelite molding, melamine molding, insert molding, micro to macro molding, double color molding, double molding, vertical, horizontal, hydraulic, pneumatic, semi automatic and fully automatic molding machine experience capacity from 5 MT. to 1000 MT., hot runner & water temperature controlling, material loading, weigh blender, dryers, inspection equipment, etc. Participating in factory acceptance tests (FATs) at the mold vendor. Leading complex projects and maintaining project timeline and budget. Developing a business case for to improving the quality and reduced the cost of molded components. Read, understand and maintain a working knowledge of Quality Procedures and Work Instructions. Providing technical process support to the organization and mentoring molding technicians.

Selecting and coordinating delivery, and the timely startup of new equipment

Establish continuously improve reliability of molding process, ancillary equipment, managing molds, equipment modification and repair

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Ensuring all molds maintain regularly and always in a condition to produce the highest quality parts

Ensuring safe and efficient molding

Interviewing and select management level employees, conducting employee performance reviews

Maintaining safety standards throughout operations, establish and maintaining a positive culture for employees

Proven powerful knowledge and wide experience of mold designs and development (tooling, polishing and hard chrome), jig fixtures, polymer & co-polymer processing and injection molding of hi-tech engineering industrial product

Reliability Engineering:

Expertise reliability in design & development (Stress-Strength Analysis, FMEA, FTA, tolerance & worst case analysis, reliability modeling & reliability prediction. DFX (assembly, manufacturability, service) parts & system management.

Excellency in reliability testing (test planning, protocol development, sample size selection, ALT, HALT, RGT, HASS). Using of reliability tools like Weibull, ALTA.

Reliability fixtures designing and development, planning and execution and reliability data assessment.

Developing & Execution of system verification and validation protocols. Medical Device, Equipment, Machine and components plus their Packaging Manufacturing: Assisting and mentoring for engineering and project management activities related to the start-up, operation of various medical device manufacturing & accessories in accordance with design, operation theatre & hospital equipment manufacturing, healthcare & Pharmaceuticals products, orthopedic device for limb lengthening, using 5 Whys in troubleshooting, 6M, quality improvement and problem solving, quality tools, fixtures, tooling. Utilizing effective and efficient Quality Engineering techniques like risk analysis, test method development, design of experiments, statistical data analysis, and development of sampling, conducting design verification studies, plans during product development cycle, verification and validation, performing dynamic test HASS, shock, leak, suction tests and create acceptance criteria for pressure used design & executing test equipment validation and performing IQ, OQ, PQ and many more as per client requirement. All Major Packaging Formats designed, manufactured and supplied nationwide & globally for OEM:

Thermoforming, Guard Protection, Mounting Cards, Stock Packaging

Rollstock for automated packaging equipment

Pouches and bags for manual loading

Custom formed trays/lids/inserts for ultimate rigid protection Cost Engineering:

Hands-on experience for cost controlling, cost planning, cost advising, project procurements, post contract administration, estimating for tender and budget, preparing project planning, preparing and assessing claims and variations, negotiation and settlements, risk assessments, design and planning

Deployment and implementation end to end implementations preferably PLM in the production

Reviewing and evaluating of development proposals, providing cost, time, and labor estimates for projects

Prioritizing and scheduling work to labor and staff at sites,

Forecasting launch and completion time of project, developing and providing cost analysis of expenditures

Calculating future cost considering rise in price of raw materials, wage rate, and risk analysis

Cost Engineering with manufacturing process expertise in the areas of Injection molding, Sheet Metal Stamping, Casting, Forging, Powder metallurgy, Expertise in Costing standards and methodologies

Interpret data and determine process/product cost drivers

Possessing ability to engage and interact with a diverse team across cultures in a global environment Hi-tech precision sheet metal stamping components & fabrication: Metal stamping services have long been “MK’s” primary focus in partnering with our customers. Wide variety of equipment to handle all metal stamping needs, including deep drawn stamping and heavy metal stamping. Stamping of “MK Group” punch press operations deliver uncompromising precision in our metal stamping production process. In all, “MK” is able to offer stamping services on over 105 press ranging in production capacity from 3 tons to 1500 tons,, precision machining, turning, shaping, milling, surface grinding, welding, cold and hot forging. At “MK Group”, quality assurance and quality control, protocols encompass four aspects certifications (including ISO certification), procedures, technology and people. Each of these aspect is integral to one another. Together, they are the reason why “MK” can say it rises above the rest.

“MK” was ISO certificated and providing prototype stamping as require, precision metal stamping, rapid stamping, production stamping, short run stamping, progressive stamping, custom stamping, four slides/multiple slides, deep drawn, copper stamping, brass stamping, aluminum stamping, stainless steel stamping, MS stamping & many more

Precision Sheet Material Operation Process Skills: Manufacturing of precision engineering & industrial sheet metal stamping, cutting/blanking, punching, slotting, perforating, notching, nibbling, lancing, slitting, parting, cut-off, trimming, shaving, deep drawn components. MUKUND KAMDAR 609-***-****

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Spectacular knowledge of aluminum, beryllium-copper, beryllium nickel, blue spring steel, brass, bronze, cold- rolled & clod annealed (CRCA), copper, copper clad, stainless steel, mild steel, spring steel, nickel, nickel iron, nickel silver, phosphor bronze, silver, tin, titanium, tungsten, zinc, wire-cloth (ferrous, non-ferrous and alloy etc.), foundry process for aluminum, MS, SS sand and die casting alloy and non alloy, machining & mfg. assembly. Managing multiple sheet metal & structural light & heavy duty fabrication, metallurgy, MS, SS, copper, brass, aluminum fabrication, Heat treatment, powder coating & spray painting, anodizing, electroplating on plastic components, reflectors for different applications & ferrous, non- ferrous plating, send blasting, acid itching, cleaning, deburring, polishing & many more as per customer's requirements, specifications & drawings. Ferrous and non-Ferrous Material Engineering:

Performing various mechanical Engineering projects and Material Testing

Collecting and analyzes data presenting reports in requested formats

Providing materials analysis support with the manufacturing departments

Performing failure testing for understanding of material properties in blank materials received for part forming from outside suppliers

Liaison with MAP materials group for materials related concerns and changes

Developing materials system to understand and predict materials impact as it relates to Stamping/ materials forming operations

Operating and maintain Stamping Materials testing equipment as well as strain analysis equipment

Supporting Stamping Department Business Plan themes as well as special projects

Developing optimum guideline for material forming operations and tooling operation.

Performing various metallurgical and non destructive testing and report findings

Confirming materials properties on materials received for forming operations

Working within a production Environment and in a team environment

Effectively summarize report findings

solving material related problems of moderate complexity

Performing manual related tasks (cutting, mounting, polishing test samples, install and maintain test equipment)

Reading and understanding technical documents and specs ( AutoCAD/Catia)

Metallurgical testing( Microvickers and Rockwell hardness, Strain analysis, bulge testing, tensile testing, X-ray, Argus, laser scan)

Understanding of materials chemistry and properties as it relates to Stamping metals/ materials forming

understanding of materials development and production techniques as it relates to Ferrous and aluminum sheet production

ACHIEVEMENTS:

Managing MK Group of Industries having seven companies in 4 locations, 2 shifts, 17 manufacturing production facilities, more than 1764 most complicated OEM products, over than 56000 SKUs, supervising 650+ employees, supplying to Government and Semi Government enterprises all over the country, sales network over 200 OEM manufactures, 85 multinational Companies, 1200 dealers, 30 Agents, 45 C’Dot telecom license manufactures, 120 construction companies (builders) all over the country & export to 40 countries worldwide. “MK” have received most credit worthy & prestigious several national awards. RECOGNITION & AWARDS:

Best Innovative Product of the Year 2012 award from Rural Development Minister for State of Maharashtra, India

Achiever of the Millennium national award from Union Minister for Information & Broadcasting of India for significant achievement in the Indian Telecom Industry

Pride of India national award from Urban and Rural Industrial

Life Time Achievement national award from Governor of Assam & Karnataka states, India for outstanding achievement in Telecom Industry

Rajiv Gandhi Shiromani national award from Governor of Tamilnadu states, India for outstanding individual achievement

Pride of the Millennium national award from Union Minister of Chemicals & Fertilizers of India for the Challenges in the New Millennium in the Indian Telecom Industries

Hind Rattan national award by president of India for outstanding service in the field of telecommunication for outstanding services

Certificate of Recognition from CGM (Chief General Manager) for significant cost improvement for the state Govt. of Maharashtra, India

Letter of Appreciation for indigenous Technology & Manufacturing of sophisticated Telecom Products from the Ministry of Telecommunication, India

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