BINAYAK ROY

• Around *.* years of experience in Manufacturing Industries in process optimization &

SUMMARY

establishment in assembly line.

• Currently working in Integrated Engineering Solutions (IES) a division of L&T Ltd. in

MES group as a Manufacturing Engineer.

• Onsite deputation to a leading tractor manufacturer in Mexico for productivity

improvement project.

• Worked on the Lean concepts & reduction of wastes/bottlenecks in assembly line by

Muri, Mura & Muda analysis, Yamazumi charts.

• Worked extensively in Quality tools and techniques, work standardization, cycle time

analysis, VSM, PFD, PFMEA & Control plan.

• Understanding of all aspects governing quality improvement activities, resolve and

address all the Quality related issued as per the industry standards.

• Strong team builder with proven ability to motivate team members towards achieving

company targets. Excellent client management skills innate ability to build strong,

lasting and mutually beneficial relationships.

• Enhance the production process operations optimize resource & capacity utilization;

escalate productivity & operational efficiencies; while curtailing costs & expenses.

• Bachelor of Engineering in Mechanical with aggregate of 79.8%

EDUCATION

AutoCAD

• : 2D Drafting

SOFTWARE

Solidworks 2011 : 3D Modeling (Basic Level)

•

SKILLS

• Timer Pro & Proplannar : Time Study, Line Balancing, Assembly sequence planning.

• Deep Exploration : for creating Visual Work Instruction for Shop floors.

• e VSM : for creating Value Stream maps

• MS-office.

ENGINEERING • Work Standardization, Lean Manufacturing, Project Planning/ Execution/ Mgmt.

SKILLS

Imrocess taImprovement/ennotilitiation. PFD, FMEA, Control Plan, Poke Yoke

P plemen tion, ManpowI r U va z on,

•

• Requirement analysis, concept generation for design of tooling & fixtures for assembly

line, coordinating with offshore for the design & implement at onsite (client end), in line

with Lean manufacturing concepts.

• Root cause analysis of quality issues through 5-why analysis, 7QC tools.

Exposure to TPS, SPC, TPM, 5S, Kaizen, 3G, 3S, 8D, VSM, JIT, KANBAN.

•

• Cycle time improvement, PMTS & Basic MOST implementation, Training & mentoring

of manpower, Team building.

PROFESSIONAL L&T IES, Chennai, India

(May 2011 – till date)

EXPERIENCE

L&T Integrated Engineering Solutions, a Strategic Business Unit of Larsen & Toubro Limited,

an $11.7 billion Engineering & Construction conglomerate. L&T IES provides engineering

design services to Automotive, Earthmoving machine Industries & Industrial Products.

DESIGNATION: Executive - Manufacturing

Honda Motorcycles and Scooters India Pvt. Ltd., Manesar, India

(Jan 2011 - May 2011)

L&T Integrated Engineering Services

08 May 2011 Page 1 of 5

BINAYAK ROY

Honda Motorcycle & Scooter India Pvt. Ltd (HMSI) is a fully owned subsidiary of Honda

L&T Integrated Engineering Services

08 May 2011 Page 2 of 5

Motor Company Limited, Japan. Honda is the world's largest manufacturer of two wheelers.

It is the fourth Honda automotive venture in India, after Hero Honda, Kinetic Honda Motor

Ltd and Honda Siel Cars India Limited.

DESIGNATION: Executive - Assembly Frame

Visteon Climate Systems India Ltd., Bhiwadi, Rajasthan, India

(July 2008 - Jan 2011)

It’s a Joint – venture between Visteon and Maruti–Suzuki. It’s the major supplier of

Radiators, Heater cores, Intercoolers and Engine cooling modules, Fuel Delive ry Modules to

Maruti–Suzuki & M&M. It is the recipient of SHINGO Silver Medallion for operational

Excellence.

DESIGNATION: Engineer – Manufacturing (Fuel Delivery Module Division)

PROJECT 1: FACILITY OPTIMIZATION & EXPANSION FOR FUTURE

PROJECT

PRODUCTION RAMP UP

HIGHLIGHTS

Period: Feb-13 to Mar-13

Customer: Tractor OEM (Mexico)

Role: Plant Engineer (Offshore)

Contribution:

• Understand the existing process flow & Develop the current state VSM.

Detailed scenario analysis of product line, factory floor space & manufacturing lines.

•

• Expected manpower increase & corresponding requirement for parking, cafeteria, admin

office etc.

• Additional storage space for inventory.

Overall material flow.

•

Layout creation based of scenario and carried out the corresponding area.

•

Additional machine plan year wise for all scenarios.

•

Evaluation of takt time for individual product line & operation.

•

PROJECT 2: CYCLE TIME STUDY & ERGONOMIC ANALYSIS OF 6 PACK 9V CELL

TEAR DOWN OPERATION

Period: Dec-12 to Jan-13

Customer: Leading FMCG Manufacturer (USA)

Role: ME/IE (Offshore)

Contribution:

• Tools used: Timer Pro, Movie maker, Excel (for video analysis), Delmia V5

• Video Time study of the rework station for cycle time of elemental activities

• Grouping activities for VA/NVA along with team lead review for Muri, Mura and Muda

analysis.

• Modeling: 3D modeling of all related products/tools to be used by operator in process:

• Simulation: creation of Human simulation & detailed analysis on: Operators

Reachability, Ergonomic, Posture & Vision, Tool Accessibility, Sequence of tool usage &

optimization.

• Suggested elimination of NVA’s by layout changes, new fixtures and kaizen concepts.

Ergonomic analysis of the suggested workstation for validation of the suggestions.

•

• Productivity calculation of the current & suggested future state.

PROJECT 3: IMPROVEMENT PROJECTS FOR G154 TRACTOR POWERTRAIN LINE

Period: Feb-12 to May-12

Customer: Tractor OEM (Mexico)

Role: Manufacturing Engineer (Onsite)

Contribution:

• New fixture development modification. (concept, design, built and trials online)

SOP preparation, Quality documents, OPL

•

Resolving process related quality issues.

•

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-

PROJECT 4: COMPACT TRACTOR ASSEMBLY LINE SET UP

Period: Nov-11 to Feb-12

Customer: Tractor OEM (Mexico)

Role: Manufacturing Engineer (Offshore/Onsite)

Contribution:

• Installation & commissioning support of tractor assembly line.

To support for BOM preparation, Basic Process Plan.

•

SOP preparation, Quality documents, OPL.

•

Standard operation combination chart and Line balancing on the assembly line.

•

Layout creation & Optimizing.

•

Process sequencing for all station.

•

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-

PROJECT 5: VISUAL WORK INSTRUCTION PREPARATION

Period: Aug-11 to Oct-11

Customer: Specialty Truck Manufacturer (USA)

Role: ME/IE Engineer (Offshore)

Contribution:

• Prepare Visual Work Instruction for standardization of assembly process.

Receive inputs from onsite engineer about the process sequence and standard process.

•

In depth study of each operation.

•

• Preparation of visual work instruction of each station considering the different ergonomic

and assembly factors by Deep exploration software.

• Co-ordinate between offshore team and client for the development of new tooling.

• Establish coordination between team members for executing projects within established

timeframe and on time delivery.

PROJECT 6: VIDEO TIME STUDY, MURI ANALYSIS, WORK STANDARDIZATION

AND LINE BALANCING

Period: May-11 to July-11

Customer: Leading Agriculture equipment Manufacturer (USA)

Role: ME/IE Engineer (Offshore)

Contribution:

• Tools used: Timer Pro, Movie maker, Excel (for video analysis)

• Video Time study of around 100 hrs for the defined production line for task and activities

creation, grouping as VA vs. NVA.

Team lead review followed by Muri, Mura and Muda analysis.

•

Preparation of Yamazumi charts.

•

Preparation of Standard Operation Combination Chart, Process Instruction sheet.

•

Preparation of work instruction, process sheets to complete capacity studies.

•

Submission of time study form and Line balancing sheet to client after QC.

•

• Establish a clear and prompt communication channel with the onsite and offshore (L&T,

India) team for executing projects within established timeframe.

PROJECT 7: QUALITY CIRCLE PROJECT ON DEFECT REDUCTION OF FRONT

FORK OF HONDA KWP MODEL (ACTIVA) DUE TO NOISE AND HARD SWING

Period: Feb-11 to Apr-11

Customer/ Prev. Employer: Honda Moto (HMSI)

Role: Engineer(Frame Assembly)

Contribution:

• Lead the CFT team in the project.

Do 3G process for initial study and take interim corrective action.

•

• Review each cause by why-why analysis, eliminate irrelevant causes and find the

potential causes.

• Simulate with the potential causes and review the results.

• Done corrections/modifications in the process as permanent corrective action and

implemented the use of specific consumables to eliminate the cause.

• Implementation of KAIZEN and poke Yoke to prevent reoccurrence of the cause.

Trained manpower for the modified assembly process.

•

PROJECT 8: 25% CHANGEOVER AND PRODUCTION LEAD TIME REDUCED BY

APPLYING VSM FOR MARUTI SUZUKI FDM YR9/YL6 ASSEMBLY LINE.

Period: Jun-10 to Dec-10

Customer/Prev. Employer: Maruti Suzuki / Visteon

Role: Manufacturing Engineer

Contribution

• Lead the CFT and guide them to carry out VSM for their respective areas for current

status.

• Analyze and organize the input and map the current status.

• Brainstorm to identify the improvement projects.

Map the future state mapping.

•

PDCA cycle for improvements on the identified projects.

•

& deployment ofrojeaitls bor rtesourves tfacilhtiievewirtganccationabioibyecorvetr.ategic utilization

Coordinating p av c a fle he gic en o ac i es o h a iz ount al l t j f ti s s

•

• Map the current state and compare with the future state mapping and calculate the overall

productivity improvement.

PROJECT 9: INSTALLATION AND SETUP OF NEW ASSEMBLY LINE FOR M&M

DIESEL DELIVERY MODULE

Period: Apr-10 to Dec-10

Customer/Prev. Employer: M&M / Visteon

Role: Manufacturing Engineer

Contribution:

• Installation and commissioning of Diesel Delivery Module (W201) for M&M XUV 5OO

line for mass production.

• Layout design in 2D as per marketing input with various options with pros and cons. and

finalizing with top management.

• Execution of layout including installation and commissioning with maintenance and

plant engineering.

• Coordinating with design and Quality department to establish processes and detailing of

facility layout for RFQ.

• Develop PFD, FMEA, and Control plan with cross functional teams.

Prepare SOP, WI for the assembly line.

•

Operator training for assembly line.

•

Machine Capability study, First Article Inspection (FAI) to roll out first product as per

• ISO/TS standards.

• Successfully done the customer (M&M) audit for the line PTR run and mass production.

• Standard operation combination chart and Line balancing on the assembly line by time

study

• Six Sigma Green Belt certification from AU-TVS, Chennai.

ACHIEVEMENTS

Productivity improvement project for power train line in a Tractor Manufacturer (OEM)

• in Mexico (Onsite).

• Compact tractor assembly line setup for a leading tractor manufacturer in Mexico.

• Increased production output from 295 FDM / shift to 370 FDM / shift by applying Lean

concepts and VSM for Suzuki Fuel Delivery Module YR9/YL6 assembly line.

• Successful Installation & setup of new assembly line for Mahindra & Mahindra SUV –

XUV500.

• Record 27 kaizen introducer in a month.

M&M ssfully demonstrated iutprzation ofinpace tandout focing theroducteasent blymen of

Succe FDM W201, by miliovement s plan lay redu r new p mov m semof line &

•

material and 25% Changeover and production lead time reduced by applying VSM for

Maruti Suzuki FDM YR9/YL6 assembly line.

• Got appreciation in successfully completing machine R&R study of Diesel Delivery

module, in finding correlation between a given flow and back pressure generated in air to

the flow generated at a particular back pressure in diesel (actual vehicle condition).

PERSONAL • :

E-mail accoem@r.postjobfree.com

INFORMATION • Languages known : English, Hindi, Bengali, Assamese

• Visa Status : H1B

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