Plant Engineer

SHAILENDRA KUMAR B.V.

Mobile: +91-976*******, +91-916*******

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

Enterprising leader & planner with nearly 28 years of experience in streamlining plant operations, invigorating businesses, heightening productivity and improving systems & procedure; targeting senior level assignments in

Plant Operations, Production Planning & Control and Quality Assurance with an organisation of high repute

Profile Summary

Directed production activities with strategic utilization of available resources & machine loading as per production schedules; executed cost saving techniques to achieve substantial reduction in terms of maintenance expenditure, man-days, purchase, raw materials & energy consumption

Conceptualized & implemented new systems and process improvements in coordination with the Corporate Team for productivity improvement by reduction of cycle time, rejection rate, machine & die breakdowns to increase machine availability hours & cost improvement

Successfully reduced production cycle time by 15% using ECRS technique, minimized plant rejection rate by 20%, and increased plant cost efficiency by 10% at Endurance Technologies

Set a landmark in minimizing variable cost like indirect manufacturing cost, energy & manufacturing costs through effective utilization of manpower, equipment, facilities, materials, and capital employed

Proven expertise in managing High Pressure Die Casting, GDC, Sheet Metal, Fabrication, Machine Shop, Paint Shop & SPM Cell

Established processes, streamlined workflow and created work environment to enhance productivity

Core Competencies

Plant Operations Management Production Planning & Control Quality Assurance

Process Design & Improvement Inventory Management HSE Management

Liaison & Coordination Resource Management Compliance

Organizational Experience

Since Aug’08 with Endurance Technologies Ltd, Aurangabad, Maharashtra.

Key Result Areas:

Planning & controlling all plant operations and ensuring the achievement of all output targets in terms of productivity, quality, cost, delivery, safety, team morale, inventory & cash profit

Supervising all production operations including technical inputs for innovative methodologies, identifying areas of obstruction and advising on process changes of site activities for improvements

Ensuring 100% compliance to all statutory requirements

Developing cost & function pillar for all functions within the plant to ensure meeting of plant objectives

Preparing & maintaining monthly P&L and MIS reports

Strategizing monthly production plan as per plant capacity & customer schedule

Executing production plan based on customer delivery requirement till the dispatches to customer

Formulating policies & procedures to ensure the effective utilization of plant, equipment & resources and achieve maximum production efficiency & quality targets as per plan

Monitoring of production targets by optimizing OEE

Implementing preventive & predictive maintenance schedule as per the plan to achieve the targeted quality production

Administering quality testing of all incoming raw materials, in-process product and of finished product with defined parameters and providing support in case of any discrepancies/ issues

Meeting PPAP/APQP & customer specific requirements

Coordinating for quality audits of product & process at in-house & supplier-end and monitoring supplier vendor rating & developing new suppliers

Reviewing the availability of raw materials & machinery spares at stores and tracking & controlling indent

Collaborating with Corporate & Plant Purchase Team for ensuring most cost-effective purchase of raw material / non-BOM items

Facilitating morning meetings to review parameters of PQCDSM on a regular basis

Steering:

oMonthly meeting with Union Committee Members to discuss current production achievements & its gaps; setting up teams to achieve targets and settling wage agreements as per terms

oManagement review meeting & safety review meeting on a monthly basis to review plant objectives & safety status

oSafety week in the plant in line with the safety policy of the organization

oMonthly meeting with Union Committee Members to discuss current production achievements & its gaps

Adhering to:

oSafety, environment & health standards of EMS/ OHSAS and regularly monitoring the same

oSafety norms by all personnel in their respective department to achieve the zero accident goal

Delivering leadership & direction to all plant staff and reviewing performance of all functional heads on a half yearly basis to bridge gaps & achieve KRAs

Recruiting & leading talented and motivated team including Line Managers, Supervisors and Operators

Highlights:

Initiated successful implementation of Total Productive Manufacturing, resulting in an increase of production by 10%, savings by 15 % in production cost as well as through effective use of the rotation method for defect & rejection

Reduced inventory carrying cost by minimizing FG & WIP through effective MOQ planning with customer, outsourcing agency & sub-vendors

Showcased training & development skills by imparting on-the-job training to team for 5S implementation at shop floor

Worked as Corporate Management Representative for quality standards like IATF16949:2016 for Waluj Casting Cluster Division which includes High Pressure Die Casting, Low Pressure Die Casting, Machine Shop & Paint Shop Division

Built high-performing teams for driving Cost Reduction Projects like Energy, Manufacturing Cost, and so on

Accomplished cost savings by tracking & monitoring Plant MIS for RM, Variable & Fixed Cost on a daily basis

Received Annual Best Safety Plant Award by MD for encouraging Plant Team to maintain zero accident

Played a major role in implementing:

oSingle Piece Flow System in the plant

oNew inspection techniques & production operating system like Cockpit for process monitoring & interlocks for sustained outputs

Executed people management skills by:

oConducting Prahansa Award for staff / workmen on a quarterly & bimonthly basis for driving improvements or Kaizens on productivity improvement, cost, quality & safety

oEngaging all plant employees in Yearly Idea Fest based on new theme and winners were awarded by MD

oGiving spot appreciation to all employees for Kaizens on P, Q, C & S

oSuccession planning of key positions in the plant

Delivered consistent success in identifying areas of bottlenecks & breakdown and taking steps to achieve zero accident & customer complaints through the application of troubleshooting tools like root cause analysis

Implemented operational techniques for reduction in cycle time & identification of improvement opportunities and cost reduction measures to achieve substantial reduction in production expenditure

Acquired extremely important approvals from concerned authorities including JIPM consistency. Japan, IATF16949:2016 from TUV NORD &EMS/OHSAS Certification by TUV NORD.

Turned around the company from losses at 10 % per annum to a path of profitability with profits to the tune of 15 %

Previous Experience

Nov’07-Aug’08 with Birla Perucchini Ltd. (Yash Birla Group), Aurangabad, Maharashtra as Manager

Highlights:

Played a key role in developing:

oPoka Yoke Oiling of Components Machines to segregate part mix up in line with proper oiling to avoid rust (Major Customer Complaint)

oPoka Yoke Punching Fixture to avoid part mix up of wheel cylinder

oInternal Cleaning Machine for proper cleaning of components

Feb’99-Oct’07 with Aurangabad Motor Manufactures Ltd. Aurangabad, Manager-Production & Quality

Highlights:

Successfully developed new suppliers for Gravity Die Casting Post Operations Activity, Machine Shop with Conventional, SPM, CNC & VMC Shop

Designed new gauges for online process checking of components

Played a major role in developing satisfactory PPAP for 45 Gravity Die Cast Parts

Steered efforts in securing ISO/TS16949-2002 Certification

Jan’97-Feb’99 with Glittlager (India) Ltd., Bi Metal Bearing Plant, Aurangabad as Senior Supervisor

Jun’96-Nov’96 with Videocon Appliances Ltd., Refrigerator Division, Aurangabad as Engineer

Dec’93-May’96 with Indo Swiss Jewels Limited, Hosur, Tamil Nadu as Shift Engineer

Aug’90-Nov’93 with Rajanhally Industrial Enterprises, Davangere, Karnataka as Assistant Engineer

Education

BE (Production Engineering) from Mysore University in 1990

Technical Skills

MS Office & SAP

Personal Details

Date of Birth: 20th March 1968

Languages Known: English, Hindi, Kannada, Marathi, and Tamil

Address: S.No.142/2, H.No.2, Vishwatara, Near Ayyappa Temple, Satara Parisar, Beed By Pass, Aurangabad-431001

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