Engineer Engineering

C-***, AIRCASTLES,HINJEWADI,PUNE

PH: +919********* +1-928-***-****

E-MAIL- **********@*****.***

HUDSON GEORGE THOMAS

INTRODUCTION

An ardent automotive enthusiast with a total of 9+ years’ experience in the field of Manufacturing Engineering, Process Planning, Facility Planning and Vehicle Assembly. Associated with launch of 5 Vehicles including 2 Greenfield programs and 1 Brownfield program. I have worked and implemented projects in US, Germany, China, Thailand & India. In the recent job role, I have set up the Vehicle Planning Team in India to support Mercedes Benz Germany & US Plant. The job involved preparing strategy, discussion with German & US counterpart, recruitment & Ramp up of the Operation from 2 Member team to 45 member team. Experienced in data analysis, I am leading the Innovation & IP task in Mercedes Benz India operation. I am also a panel member in the Future of Manufacturing (FOM) to nurture and develop ideas with internal & external startups.

WORK EXPERIENCE

2016 Apr- Present<Support Sprinter Assembly Line, Dusseldorf Germany & Charleston US>

Mercedes Benz Research and Development India Pvt Ltd

Montage Planning (Assembly Mercedes Benz Sprinter)-Senior Technical Lead for the Team.

Manufacturing Support for Final Assembly. Supports various Final assembly projects. Good knowledge on Sprinter Models (VS30/NCV3). Good exposure to Dialog, ACM, Engineering Client & Proplan

-Assembly & Ergonomics Simulations-DELMIA V5

-Robotics Simulation and Tool Path Planning-DELMIA V5

-Nut Runner accessibility Study for new models.

-Time Study using MTM.

-Assembly line Layout planning & AGV’s-DELMIA V5 & Plant Simulation

-Data vaulting of Equipment for Engineering client

-SPM Development to suit future model requirement

-Leading the eSprinter (Electric Van) DFA & DFM responsibility.

2015 June-2015 December

Ford India Private Limited, Sanand

Trim Coordination Build & Process Capability - VOME -68 JPH-3 Models

Lead team of 3 for Engineering Buck/Trim Coordination Build. Handled the Fit and Finish targets for Ford Ka for Europe Market. Handled Process capability – of EOL Filling Machines & Class A fastenings.

2015 June-2015 December

Ford of China, Hangzhou, China

Trim Coordination Build, Lead-Brown Field Project-Vehicle Quality-55 JPH-2 Models

(Ford Taurus-Lux Sedan, Ford Edge-SUV)

Responsible for coordinating Rear End Vehicle Fit and Finish activities across Body Shop and Supplier base. Role mainly dealt with RCA of Fit & Finish issues and recommendation to solve the issues before next build.

-Proactive Measure, Analysis and Action Plan for Vehicle Fit & Finish requirement.

-Part Coordination trials at supplier end to prove Capability.

-Engineering Buck Analysis for various Plastic and Sheet Metal Parts.

-Coordinated the MP1 and MP2 Concern resolution with CFT.

-Data driven Analysis to Management on What Next.

-Quick decision driven from Measure and Analysis Strategy.

-Tuning on Product Design based on Mock up and Measurement Analysis.

-DPU reduction and fast Containment actions.(ICA Implementation)

-Advanced usage of Digital Mock Up application to drive the actions.

-Implementation of Prussian Blue Matching, Dental Wax Mould, 3D printing to get ahead of the problems.

-Completed Six Sigma Green Belt & worked under Six sigma Master Black Belt.

2014 Jan-2015 May

Ford India Private Limited, Sanand

Manufacturing Engineer- Green Field Project-Vehicle Assembly-68 JPH -3 Car Models

(Ford Figo-5Dr, Ford Aspire-Sub 4Dr, Ford Ka-4Dr)

Coordinated Feasibility for Assembly and Manufacturing from VP build to Job 1. Digital Mockup of Assembly Process and Tools. Handling Aid Installation and Commissioning. Lead Simulation Study and Bottleneck analysis in Assembly Flow.

-Process Planning and Work Station readiness.

-Multi Model Assembly Line Balancing

-AIMS-Lead for Vehicle concerns through Automated Issue Management Systems.

-SME for Global Manufacturing Requirement (Must & Wants for Process).

-SME for Water Management & Testing.

-Implemented Innovative Kitting Concept with horizontal deployment in Asia Pacific.

-Ergonomic Analysis for Vehicle Assembly and design input

-Benchmark study of other models for Assembly feasibility.

-Handling Aid and SPM development.

-Error proofing of part selection using AIS (Automated Information system).

-Mock Up study using Siemens Vismock Up

.

2013 Jan-2013 Dec

Mahindra & Mahindra, Mumbai & Chennai

Assistant Manager – Brown Field Project –Vehicle Assembly-18 JPH- 3 Models

(Mahindra S101-Mini SUV, Mahindra XUV 5OO Hybrid, Verito Electric)

-Prepared RFQ’s for Filling Machines, Roll Brake Tester & Wheel Alignment Machines and Manipulators.

-Design and Implementation Decking Trolley for Engine and Rear Axle assembly

-Manufacturability feasibility Study(Operator Reachability &Tool access).

-Execution Change Management, Facility & Cost Impact.

-Concept design and development of assembly fixtures and Tool Aids.

-Planning of Material stream of Kitting, Sequencing and Line side storage.

-Defined the requirement and concepts for Manipulators for General Assembly.

2009 Oct-2012 Dec

Mahindra & Mahindra Ltd, Chennai & Chakan

Assistant Manager – Green Field Project –Vehicle Assembly-18 JPH- 1 Model

(Mahindra XUV 5OO-SUV)

Started from the incubation of Vehicle Prototype build to Final Ramp up Production of XUV 5OO. Worked on various field from assembly feasibility to Productivity Improvement.

-Process Engineer- Global XUV5OO

-Assembly Line Balancing for different JPH configuration

-Defined the Process Sheets for all the operations in Door line.

-Interacted and given input to design for part Poka Yoke, Torque Standardization

-Tracking and resolution of the build concerns FTG, Process & Design

-CFT team member for reviewing PFMEA for Door line operations

-Created Must and Wants of manufacturing Requirement.

-Time Study using basic MOST (Maynard Operation Sequence Technique)

-Planned and implemented Material storage and line side layout for door assembly line

2005 June-2006 June

Godrej & Boyce Mfg Co Ltd, Mumbai

Diploma Engineer Trainee- CNC Dept & Lock Division

Worked in various departments of CNC Machining, PPC, and Material Management.. Worked on Panel Dies & Aluminum Die Casting Dies. Trained from HAAS Automation USA on 4 Axis and 5 Axis CNC Milling Centers.

- CNC programming and Machining experience in HAAS 4 Axis VMC

- Familiar with Fanuc Programming and controller

- Datum selection and Job setting of Dies and Moulds in VMC’s

- Standard Time Calculation for Lock Assembly using Video Analysis

- Design and fabrication of Quick assembly fixtures

ACHIVEMENTS

PROFESSIONAL

CORE

COMPETENCIES

CO

INTERNATIONAL

EXPOSURE

HOBBIES &

ENGAGEMENT

EDUCATION

ACHIVEMENTS

COLLEGE

PERSONAL

PROFILE

-West Zone Runners Up in Auto Quotient Telecasted by NDTV – Dec 14 (1.4 Lakh Participants)

-Productivity Award in 5th International Automotive Engineering show held at Pune.

-Mahindra Rise Award for Project “Kitting Concept (Lean Manufacturing) Implementation in door line for Alternative Thinking category.(1 out of 16 teams featured in Mahindra Rise Coffee Book in Automotive and Farm Equipment Sector.)

-Winner of WOW feature Contest ‘a future Project’ been developed by R&D and assisting the team to develop the same.

-Spot Award for Support provided for Ramp Up of XUV 5OO in Chakan

-Won “Excellerator Award” for demonstrating a good team work and application by resolving many post installation, ramp up issues as the window personnel for the CME team after SOP at Chakan

-Won “Excellerator Award” for developing the ‘Door kitting Concept” which is effective in reduction of approximately 16 lakh fixed cost and 1.2 lakh Running Cost ( Reduction of NVA to less than 20% of total work content in door line)

-3rd Prize Winner of AQ (Auto Quotient) contest across all 10 sectors (Including Farm Sector, Tech Mahindra,Mahindra Two wheelers- 2222 first round winners)

-Wild Card Entry to Royale Great Escape Rally covering 2800 Km in Rajasthan.

-Open Auto Quiz Runner Up IIT Madras

-Trained Off road bashing at Mahindra Adventure Academy

-Quiz winner on Agriculture by Mahindra Farm Sector.

-Quality Quiz Winner conducted by Business Excellence Team.

-Runner Up in General Quiz Contest conducted in MRV Chennai.

-Winner of Sustainability Quiz Contest conducted in MRV Chennai.

-Winner of Information Security Quiz Contest conducted in MRV Chennai.

-Proficiency in CATIA, PRO-E, Autodesk Inventor, Solid Works, AutoCAD, VisMockup, NX, Delmia,

-Knowledge on PFMEA, DFM, GD&T.

-Design knowledge to develop facilities from scratch.

-Animation knowledge in Inventor & Vismockup.

-Knowledge on Poka Yoke, Lean Manufacturing, Productivity Improvement.

-Knowledge of Visual Mock Up software for Part study analysis.

-Familiar with Service and Maintenance (SAM)- Design requirements.

-Knowledge on Roller & Brake Tester and Wheel Alignment Machine

-Knowledge of Brake, Coolant, AC and Power steering -Filling Machines.

-Experienced in CNC Programming in FANUC controllers.

-Knowledge of PLC, Pneumatics and Electronics & Basic Automation

-Familiar with Rapid Prototyping Technology (RPT) & Blue Ray Scanning

-Skilled on A2MAC1 and benchmarking process

-Knowledge on Glass Glazing Machine & Roof sealer machines.

-Mercedes Benz Vans, Charleston, USA - IPV2 (AVO’s & Line Balancing)

-Mercedes Benz Vans, Dusseldorf, Germany (Equipment’s & AVO’s)

-Ford SUV & Lux Car,Hangzhou, China (Cubing/TCB –Exterior Quality)-

-Ford Small Car, Koln Plant (VP Build)

-Ford SUV, RayongThailand (Conveyor Installation)

-Travel, Driving, Bike Riding & Photography;

-Automotive Blogging and Content writing for Magazines and Newspapers.

-Consultant to IIT Madras Incubation Centre.

DEGREE

INSTITUTION

SPECIALISATION

YEAR

CGPA

%

B-TECH

COLLEGE OF ENGINEERING

TRIVANDRUM

MECHANICAL

ENGINEERING

2009

7.41/10

74.95

DIPLOMA

K.G.P.T.C,CALICUT

TOOL& DIE

2005

81.0 %

SSLC

K.R.K.P.M.B.H.S,KADAMPANAD

2002

88.5%

- - Selected Candidate to Visionary Leadership Program by IIMC

-All India Rank 254 in Common Entrance Exam for Design for M’Des in IIT’s

-All Kerala Lateral Entry Test (LET) 3rd Rank holder.

-Gold Medallist in Tool & Die Engineering. Passed in 2005 with 81.78%:

-Winner of Prestigious Malayala Manorama Scholarship.

-Secondary: SSLC Passed with 88.5 % from K.R.K.P.M.B.H.S, Kadampanad, in 2002.

-Centum in Physics Subject

-Scholarship for Topper in Science Subjects.

- Winner of Mechanical Quiz held at Govt College of Technology Coimbatore

- Winner of Technical Quiz held at LMCST Trivandrum

- Winner of CAD Design held at LMCST Trivandrum (2 Times in 2008 & 2009)

- Winner of Model Drawing held at LMCST Trivandrum

- Runner Up in Product Design held at PAACET Trivandrum

- Runner Up in CAD Design held at GECB Trivandrum

- Runner Up in Junkyard Wars held at MBCET Trivandrum & SCT Trivandrum

- Consolation Prize in Glider Contest held at GCT Coimbatore.

- Finalist in Desmond Event conducted by IITM

- District Level Winner in Various Water Colour and Pencil Sketching Contest

- Editor in Chief ‘70th Year College Magazine.

- NCC A& B Certificate Holder and Attended NIC at Delhi and AAC in Trivandrum

- Volunteer in NSS activities.

Date of Birth : 05-09-1986

Nationality : Indian

Sex : Male

Marital Status : Married

Languages known : English,Hindi, Tamil, Malayalam & German A1

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