Engineer Six Sigma

J. RATNA BHOOSHANAM

Mobile: +201********* ~ E-Mail: ***********@*****.***

Seeking assignments in Designing & Moulding / New Product Development /

Budgeting with and organisation of high repute, preferably in manufacturing

industry

PROFILE SUMMARY

< A dynamic professional with 13 years of rich experience in New product

development, research & development, Mould manufacturing and Mould repair

activities with key focus on top line profitability & optimal utilization

of resources

< Strong abilities in creating, reading & interpreting engineering drawings

with proficiency in designing & developing new products in conformance

with pre-defined technical specifications

< Possesses a clear understanding of latest technology trends in the

area of Mould design, Manufacturing and Repair

< Demonstrated abilities in enhancing product design, performing process

failure mode effects & analysis, optimizing resource utilization,

escalating productivity and operational efficiencies

< Visited Singapore, Malaysia, Thailand, Germany, UK and Czech Republic

for exploring possible improvements in mould design/ mfg. processes/

design training & efficiency improvement in bottle manufacturing

< Possess excellent communication, creativity, innovation, problem

solving and coordination skills

AREAS OF EXPERTISE

< Coordinating the entire product development cycle including requirement

analysis, planning, monitoring, prototype development and overall testing

< Product design and Mould design for variety of glass containers ranging

from 6ml to 4lit for Blow-Blow, Press-Blow & NNPB

< Mould repair and Manufacturing

< Development of Light weight bottles

< Conducting tests & inspections to ensure that products developed are in

compliance with pre-set quality specifications

< Directing the development and implementation of Mould procurement

strategies, contingency plans and ensuring that plans are aligned with

project requirements

< Overseeing production related tasks including planning, control and

trouble-shooting, setting up production targets and achieving the same

within the given time and cost parameters

< Minimizing performance bottlenecks for achieving high productivity with

minimum consumption of material & machine and monitoring expenses

< Imparting continuous on job training for accomplishing greater

operational effectiveness/ efficiency

CORE COMPETENCIES

CAD/CAM Light weighting

Manufacturing

Product Design & Development Technology Management

Resource Optimization

Quality Assurance Requirement Analysis

Team Management Six Sigma

WORK EXPERIENCE

Since Feb'13 with MISR Glass Manufacturing Co., Egypt as Head of Design and

Mould work shop

Company profile:

Misr glass manufacturing company is a reputed glass manufacturer in Middle

East region, with production capacity of 400MT /day in Flint, Green and

Amber colors. More than 50% of production is for export market.

Highlights:

< Playing major role in activities of new product development for Soft

Drinks, Juices, Jars, Liquor & other Glass Containers for BB, PB &

NNPB

< Mould designing & light weighting activities.

< Mould repair activities, mould shop administration, CAPEX & laid

budget compliance

< Internal mould manufacturing for sampling / trials

< Instrumental in procuring mould from overseas suppliers with timely

delivery & cost reduction

Sep'06 - Feb'13 with AGI Glaspac (An SBU of HSIL Ltd.), Hyderabad

Company profile:

AGI glaspac is the second largest container glass plant in India with a

capacity of 1600MT/day, having high repute for quality containers and rapid

new product development for their customers. Having 2 plants with 4

Furnaces manufacturing Flint, Green, Amber & Colored bottles.

Growth Path:

< Joined as Deputy Manager

< Promoted to Assistant General Manager (Head of Design)

Highlights:

< Led a team of 6 skilled Engineers working on Auto CAD, Pro/e &

Unigraphics

< Commercialized over 1100 new products over a span of 12 years

< Played a major role in achieving weight control to keep weight below

mean (2%) during entire span of mold life in the combination run

environment

< Essayed a stellar role in implementing Windchill PLM for Product Life

Cycle Management and was responsible for business administration of

Windchill

< Improved mold design for very complex bottles, like 2litre handle

bottle manufactured in blow-blow & achieved average efficiency of 88%

< Significantly contributed in developing:

< Consumer market tumblers & beer mugs on IS machines during crisis

times for the utilization of machines

< 3D Training software to train Human Resources on IS Machine (Bottle

Mfg. Machine). This was developed over a period of 1.5 years with a

single resource using Pro/E Modeling and Mechanism Modules.

< Training modules to train Human Resources in the areas of Quality

Control, Mould repair.

< Weight reduction of up to 15% on over 50 products for key customers

within one year.

< Efficiently worked for Green Field Project with 500 TPD capacity in

2009 & Brown Field Expansion of 500 TPD capacity in 2011, achieved

best performance with in a very short period.

< Significantly contributed in planning machine variables for various

articles for new green field projects & Brown field expansion

< Significantly contributed in planning mould equipment & procurement

for green field projects and Brown field expansion

< Significantly contributed in improving mould life and mould repair

techniques.

< Developed iconic products like SABMiller Patented Bottle, Kingfisher

Patented Bottle, Frooty, White Mischief Vodka, etc.

< Significantly contributed in establishing product specifications,

performance standards.

Oct'04 - Sep'06 with Satyam Computer Services Ltd. (Presently Mahindra

Satyam), Hyderabad as Lead Engineer

Highlights:

< Felicitated with:

< Certified as Green Belt-DFSS in using Six Sigma methodologies in

Dec'05 from GE

< Certificate of Excellence for CAD Support in Motors Control Center

Design-Requisition Team in Feb'06

< Pat on the Back award for resolving manufacturing issues to help the

shipment in Jul'06

< Instrumental in designing:

< Around 80 new Motor Control Centers as per end customer requirements

< Interchangeable mounting components for Motor Control Centers as a

part of my Six Sigma project and successfully reduced the lead time to

assemble the components by 70%

< New case sides and channels for Transition and Corner Sections

< Significantly contributed in taking challenge for solving green sheet

issues which arises in the plant due to sudden customer changes &

other manufacturing problems while fabricating the MCC

Major Project Handled:

< Motor Control Center Requisition Engineering

Client: GE Consumer & Industrial (GE C&I) - Mebane-USA & Monterrey

Plants

Role: Lead Engineer - Controls Requisition

Team Size: 3

Tools: Pro/E-2001, Pro/Intralink-3.4

Period: Oct'04 to Sep'06

PREVIOUS EXPERIENCE

May'01-Oct'04 with AGI Glaspac (An SBU of HSIL Ltd.) As Design Engineer

Growth Path:

< Joined as a Trainee Engineer

< Promoted to Engineer

ACADEMIC DETAILS

2008 B.Tech. (Mechanical Engineering) from Jawaharlal Nehru Technological

University, Hyderabad

2000 Post Diploma in Tool Engineering from Electronic Service and Training

Centre (A Govt. of India Society Under Ministry of

Industry), Ramnagar, Nainital

1999 Diploma in Mechanical Engineering from State Board of Technical

Education, Karnataka

ADDITIONAL QUALIFICATION: Master CAD/CAM from Central Institute of Tool

Design, Hyderabad

KNOWLEDGE PURVIEW

< Well versed with:

< Design of container glass bottle of simple to complex shapes & mould

equipment for IS & AIS machines using Blow-Blow, Press-Blow & Narrow

neck Press-Blow Processes

< Mould Repair and Manufacturing Techniques

< Performance standards, QC techniques for glass Containers

< Forming Simulation for Containers using GD Elfen

< 2D, 3D modeling & CNC Programming CAD, Pro-E and Unigraphics

< Windchill 10.0 CAD Data Management and Business Administration

< Manufacturing Processes on CNC and Conventional Machines

< Usage of Six Sigma Methodologies in problem solving approach

TRAININGS ATTENDED

< 1 Week Training in Mould Design from EMHART, Malaysia

< 15 Days Training in Production Efficiency Improvement from Weigand

Glass, Steinbach plant, Germany

< Forming Simulation, Stress Analysis & Impact Load Analysis from Rock

Field, Swansea, UK

< Unigraphics from Group of Engineers, Hyderabad

< Six Sigma, Reliability, NPI & PCTO Processes

< ISO Systems & SQC.

< Windchill 10.0 for Business Administration during implementation in

AGI Glaspac

TECHNICAL PAPERS

< Understanding blank temperatures in Blow-Blow process. March 2010.

This explains behavior of glass during parison formation and during

final blow due to different temperature regions and their effect on

glass distribution in Blow-Blow process.

< Thin wall light weight Containers: Its Evolution and Impact. Aug'10

for International summit for packaging industry. This explains about

advanced techniques for light weight blow-blow process, the process

for manufacturing light weight containers & mould design innovations

to achieve weight reduction.

PERSONAL DETAILS

Date of Birth 19th April, 1981

Permanent Address G1, Plot No.72, RKHS Colony, AS Rao Nagar,

ECIL, Hyderabad-500062

Present Address MISR Glass Mfg. Company, Petroleum Companies

Road, Mostorod, Egypt

Passport No. K3645195

Languages Known English, Hindi, Telugu & Kannada

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