Manager Plant

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Navendu Mohan

E-Mail: ~acgqvr@r.postjobfree.com ~ acgqvr@r.postjobfree.com,

Mobile: +91-981*******, Phone (R): +91-120-*******

Senior level assignment in SBU Head/Profit Centre Head /Plant Head with an organisation of repute

An accomplished professional [B.E.(Mechanical) from B.I.T.S, Pilani] with proven success over 25+ yrs in

- Profit Centre Operations - Plant Operations - Project Management

- Strategic planning - Process Optimisation - Supply Chain Management

- Quality System Management - Erection & Commissioning / Maintenance - Team Management

A dynamic professional with over 25+ years of rich experience in Strategic Planning, Plant Operations, Process

Enhancement, Production Planning & Control, Supply Chain Management, QA & Business Process Excellence.

Has experience of Working with Automotive OEMs/Auto-Component Manufacturing Groups of High Repute

(including MNCs): JBM Auto Ltd, Lucas TVS Ltd as Plant Head, AG Industries Ltd as Sr. GM (Works),Minda-Huf

Ltd as GM-Operations, Krishna Maruti Ltd as Sr. Manager, Trelleborg Automotive India as Sr. Manager, Maruti

Udyog Ltd as Dy. Manager etc).

Proven skills in implementing the JIT Management (Lean Management Concepts i.e. Cellular Layout & Pull System).

Formulating pre-planned developmental strategies for achievement of Business goals by identifying & developing new

avenues for long term Business Sustainance & growth.

Expertise at implementing Quality Management Systems as MR for TS-16949, QS 9000, ISO9001 & well versed with

TQM, TPS, TPM, etc.

Abilities in enhancing Manufacturing Process operations, optimising resource & capacity utilisation, escalating

productivity & operational efficiencies; while curtailing costs & expenses.

Hands on experience in Manpower Management, Industrial Relations with ability of leading large taskforces (upto 800

strength) & developing their capability by benchmarking & transferring best practices to the Plant Operations.

Demonstrated analytical, problem solving and organisational ability coupled with strong communication, inter-

personal and relationship management skills.

Formulated & implemented effective strategies & roadmap across the entire Supply Chain from In-House Production

lines till the Second Tier Supplier Base to ensure proper alignment, in-line with the needs of the Business, thereby

increased inventory turnover ratio upto 15 at Krishna Maruti Ltd. & 18 at Trelleborg Automotive.

Business Skills

Determining the future needs and augmenting production capacity for producing projected quantities of Product-Mix

as per pre-defined techno-commercial business norms/guidelines.

Overseeing Manufacturing Operations related tasks including “Yearly/Monthly/Weekly/Daily” Production Planning/

Scheduling & control & trouble shooting for achieving the planned periodic schedules including Variance Analysis.

Foreseeing the performance bottlenecks & taking timely Pro-active measures to ensure smooth Plant Operations.

Monitoring & Controlling New Development Projects alongwith CFT Leaders and development of contingency plans

if needed, to meet cost and time over-runs.

Designing manufacturing layouts and managing erection and commissioning activities of plant and machinery.

Identifying opportunities in automation, process ramp up, ensuring proper & Safe working conditions, periodic up-

gradation of facilities & utilities and their efficient management.

Implementing TPM activities on bottle-neck machines, incorporation of Predictive/ Preventive maintenance schedules

alongwith Production Planning Function to ensure optimised Manufacturing Operations.

Motivating employees by encouraging them to participate in Group kaizen activities, Suggestion scheme, participating

in various other external competitions, celebration of Quality month, Safety month and other major Promotional

Activities.

Technical Purview

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Processes: Spot/MIG Welding, Cold Forging, Sheet Metal Press Working, Aluminium Die-Casting, Rubber/Plastic

Injection-Moulding/Extrusion, CNC controlled Tube / Wire Profiling, PLC Controlled Automatic

Assembling Machines, Gear Hobbing & CNC Machining, Poly-Urethane Moulding, Surface Treatment/

Electro-plating, Painting etc.

Techniques: Lean Manufacturing, TPS, JIT, VSM, SMED, KANBAN, OEE, TPM, MPCP, VA/VE, Poka-Yoke,

PDCA, Pareto Analysis, Kaizen, DWM, 5-S, 3-M, 3-G, FIFO, DFMEA, PFMEA, SPC, MSA, APQP,

PPAP, etc.

EMPLOYMENT PROFILE

From 2nd Feb’12 with JBM Auto Ltd, Ahmedabad as Associate VP & Plant Head, responsible

for entire Business Management of the Unit:

Managing the entire Manufacturing Operations including Press Shop/Weld Shop with a strength of 500 workmen & 90

Technicians, Engineers, Managers & above.

Business Objectives & Target Planning in–line with Corporate Business Plan.

Budget preparation (Revenue & Capital) & Cost Control.

Capacity Planning, Supply Chain Development, Strategic Planning, HR Policies & organizational development.

Plant Expansion/Layout Planning & Execution.

Liaisoning with Customer/Supplier/Govt. Authorities, Deployment of Best Practices, EHS & TS16949.

SAP Module customisation & periodic implementation review.

Plant Security, Contingency Mitigation Plan, Inventory control, Emergency Medical Assistance.

From Feb’11 till Jan’12 with Lucas TVS Ltd, Rudrapur as Plant Head, responsible for entire

Business Management of the Unit:

Accountabilities:

Administering and ensuring smooth execution of business plans in line with Organizational overall growth projections.

Managing the entire Manufacturing Operations including Assembly/CNC Machining/ Stamping/ Painting/ Injection

Moulding shops with a total manpower strength of 550+ (All inclusive: Technicians, Engineers and Managers).

Performing R.O.C.E improvement by increasing Overall Equipment Effectiveness (Close Monitoring of Down Time,

Actual Cycle Time, Line starvation, Set-Up, Change-Over Time, etc).

Profitability improvement by ensuring Profit Centre Operations & identifying loss making Operational Activities with

Gap Analysis & re-establishing norms to eliminate/reduce non-value added activities.

Establishment of KPI matrix in-line with Business Objectives in terms of Short & Long-term perspective.

Preparation for both Revenue & Capital Budgets & getting approval from the Top Management.

Finalising Annual Improvement Projects for each Functional Head (along with their sub-ordinates & Monthly Periodic

Review with each HOD).

Customer Relationship Building (Jointly with Marketing) by ensuring periodic review meetings with Customers &

timely resolution of Customer open-issues.

From Feb’09 till Dec’10 with Knorr-Bremse India, Faridabad as Dy. General Manager,

responsible for Business Process Management in Operations as per Toyota Production

Systems:Accountabilities:

Performing R.O.I. improvement by increasing Overall Equipment Effectiveness (Close Monitoring of Down Time,

Actual Cycle Time, Line starvation, Set-Up, Change-Over Time, etc.).

Implementing Toyota Production systems in the Operations (Flexible Manufacturing Systems as per Customer asking

rate i.e. Takt Time) along with implementing Business Process Management Systems in-line with “EFQM Business

Excellence Model”.

Responsible for identification & implementation of KPI’s at all levels of Plant Operational processes.

Foresee smooth working of all Cross-Function Teams in a Matrix Organisation wherein proper coordination is ensured

through CFT Leaders & HODs with well defined Roles & Responsibilities & pre- defined Targets/Time-lines.

Establish Communication Channels/Forums for Concerns/Grievance Redressal for prompt/ timely handling/ resolution

of issues by ensuring periodic interaction at different levels of management hierarchy.

Synchronisation of energy –intensive processes involving Utility services to reduce the throughput time leading to

higher Productivity & Energy –savings.

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Ensuring Coordination for SAP related activities pertaining to SCM System Gaps/ Module Customisation/Up-

gradation, new module development/deployment and effectiveness monitoring.

Notable Accomplishments :

Implemented JIT Management Principles (Lean Management Concepts i.e. Cellular Layout & Pull System,

KANBAN, 5-S, Kaizen, 7 Q.C. Tools, Process Poka-Yoke’s etc.)

Defined CTQ Work Stations & Multi-skilling of Associates & Supervisors by identifying skill gaps & organising

effective On the Job trainings.

Achieved the production target of 100% (on monthly basis) and delivery performance of 98% & above.

Successfully achieved O.E.E. target of 77% (Min.) and customer PPM Level of below 100 within one year’s time.

Oct’04- Jan’09 with AG Industries Ltd, Gurgaon as Senior G M (Works)/ Plant Head:

Accountabilities:

Administering and ensuring smooth execution of business plans in line with Organizational overall plan.

Pivotal in setting up a new Plant for expanding production capacity & for commencing new product manufacturing.

Performing R.O.I. improvement by increasing Overall Equipment Effectiveness (Close Monitoring of Down Time,

Actual Cycle Time, Line starvation, Set-Up, Change-Over Time, etc.)

Managing the implementation of JIT Management (Lean Management Concepts i.e. Cellular Layout & Pull System).

Devising & implementing Performance Measurement System to streamline employee performance & Functional/

Organisational deliverables, to bring in alignment & accountability for increased business effectivenes.

Notable Accomplishments:

Up-graded the Work Culture by incorporating Best Management Practices and by empowering & facilitating

Employees & Technicians thereby increasing the Employee Satisfaction Index.

Adapted & implemented improvements related to “CII-ACMA Excellence Model” Cluster activities at IMT &

Gurgaon Plants & Maintained TS16949 Compliance & adhered to the Quality Management System down the line.

Handled effectively a team of 850 Workmen working harmoniously in 3 shifts.

Implemented Toyota Production Systems in the Operations (Flexible Manufacturing Systems as per Customer asking

rate i.e. Takt Time) specifically in the bottleneck process of P.U. Painting (conveyorised).

Achieved drastic reduction in COPQ by controlling Internal & External rejection/rework, Scrap generation from

Plastic & Extrusion processes through SPC, Pareto Analysis & PFMEA.

Implemented concept of Regular/Repeater/Stranger Part Classification to increase ITR from 12 to 16.

Efficiently implemented Data Driven Cross-Functional problem Solving & kaizen focussed working.

Planned and designed the Poka-Yoke Test Mechanisms for Defect Free Production & could achieve the Customer PPM

Level at 70-100.

Performed the effective maintenance of plant & Utilities through TPM implementation on bottleneck machines.

Improved the delivery performance to 99% and maintained O.E.E. of 75% & above.

Apr’02- Sep’04 with Minda Huf Ltd., NOIDA as General Manager (Operations):

Accountabilities:

Managing the entire Domestic Manufacturing Operations including Assembly/Aluminium Die-casting/CNC

Machining/ Stamping/ Plastic Injection Moulding shops with a strength of 650 Technicians.

Adapted & implemented “CII-ACMA Model” related to Plant improvement activities at Noida Plant.

Handled SQA initiatives alongwith Vendor Development for streamlining of 12 Core Component Suppliers to ensure

un-interrupted supply of quality Parts for the In-House assembly Lines.

Notable Accomplishments:

Efficiently increased OEE from the level of 58% to 70% by reducing Die Loading & Set-up time.

Successfully reduced inventory by incorporating Concept of Regular/Repeater/Stranger Parts through effective PPC

Incorporated TPM on Key production equipments thereby increasing the Machine up-time.

Proficiently implemented SPC on all critical to Quality operations.

Upgraded the Product Quality Index vis-à-vis Competitor’s Products.

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Managed the QMS Up-gradation at Core Suppliers to ensure 100PPM In-coming Defect Rate (Max.).

Actively involved in Incorporation of POKAYOKE testing/inspection mechanisms/Fixtures on the Assembly Lines to

ensure defect-free Product launches.

Aug’98- Mar’02 with Trelleborg Automotive-India, Sahibabad as Sr. Manager (Prod) &

MR:

Accountabilities:

Supervising and managing a team of 200 people, ensuring optimum performance of manufacturing operations.

Developing system based management i.e. ERP (MFG-PRO), QS9000 and TPM, thereby increasing the customer

satisfaction.

Executing cost saving and energy saving techniques/ measures and layout modifications to achieve substantial

reduction in Expenditures vis-à-vis targeted/sanctioned budget.

Planning & controlling maintenance schedules while curtailing operational costs / expenses by reducing unwarranted

break-downs of key machines / utility equipments.

Notable Accomplishments:

Headed projects for process re-engineering with demonstrated abilities in enhancing productivity & capacity

utilization with focus on maximizing operational profitability by having a close monitoring on Shop’s OEE.

Reduced Customer Complaints/Rejections significantly by implementing a CFT work culture & utilising techniques

like DMAIC, FORD’s 8-D Problem Solving Tools.

Rubber Moulding/Extrusion Shop’s OEE was brought up from 55-60 % to 70-75% by introducing effective

Predictive/Preventive maintenance along with TPM activities on bottleneck machines.

Initiated action plan for improving the morale of people by incorporating open forum on resolving IR issues.

Significantly contributed in implementation of QS 9000 across the company as MR.

Curtailed the COPQ (Cost of Poor Quality) to 50% in a period of 3 Years, by implementing a CFT work culture

enabling efficient & prompt rectification of problem areas working closely with QA.

Successfully brought down customer rejection from 750PPM to 150PPM in a period of 3 years by strengthening

Customer Representatives alongwith their CFTs.

Jan’93 - Jul’98 with Krishna Maruti Ltd, Gurgaon, as Sr. Manager-Prod. (Also worked as

Manager QA & MR), [Also Deputed as Director at Krishna Car Trims-Faridabad]:

Manufacturing, Production Engineering and R & D:

Entrusted with responsibility of line balancing of Assembly, Paint Shop, P.U. Shop & Weld shop operations at KML, in

co-ordination with Japanese Advisors & SNIC trained engineers. OEE was up-graded to 75% in 2 Years time.

Spearheaded the reorganization of Production Engineering function, devised/implemented the Productivity norms as

per the guidelines issued by the Japanese Collaborator.

Steered the projects involving erection, commissioning of plant & the R&D facility within the set time/budget/quality

parameters at KCTL & KML respectively.

30% Floor space saved by modifying the plant layout in-line with Modular Cell concept.

Reduced job change-over time from 35 minutes to 8 minutes in power press by using SMED techniques at Sheet Metal

shop at backward integrated Plant in Faridabad.

Set up of special testing Lab. for carrying out seat testing & ensuring conformity to the homologation regulations

(EEC/ECE). The company received recognition as In-House R&D Centre from Department of Science & Technology,

Government of India.

Nov’84 to Dec’92 with Maruti Udyog Ltd, Gurgaon, as Deputy Manager:

(Worked in both Production Division & Quality Assurance Division):

Managed the production operations at Car/Omni/Gypsy Vehicle Assembly/ Engine & Transmission Lines &

accomplished the production targets.

Devised & upgraded the Training Modules as per Maruti Operation’s Standards.

Ensured “First Time Right Performance Index” to 80% level.

Functioned as Section Manager in Proprietary Section cum Endurance Testing for Parts Inspection Department.

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Actively participated in VA/VE activities with key focus on achieving substantial cost savings.

Commenced career with Escorts Ltd, MSD(Motorcycle & Scooter Division), Faridabad as

Production Engineer from Jun’82 to Oct’84:

Looked after Gear Machining shop (Blank machining & Gear Hobbing) as Production Shift Engineer.

Trainings Undergone

“Company Wide Quality Control & Productivity Enhancement Programme in-Line with Toyota Production Systems”

at SNIC, Japan (Duration: 2 Months).

“QMS & Productivity Improvement”, Australia (Duration: 1 Week).

Metrology & Gauge Control, HAL, Bangalore (Duration: 2 Months).

R&D Test Set-Up Certification at INSTRON, DARTEC, UK (15 Days Each, Two Visits to U.K.)

Qualified the Lead Assessor’s Course of ISO9000 from M/s Alan A. Griffin Associates of U.K.

Academic Credentials

1982 B.E. (Hons.) Mechanical from Birla Institute of Technology & Science, Pilani (Raj.) with 7.78 CGPA out of 10.

Pursuing PGDBA (Operations Management), Distance Learning Course from SYMBIOSIS, PUNE.

Personal Details

Date of Birth: 16th April 1961; Address: F-114, Sector 41, NOIDA, PIN-201301; Linguistic Abilities: English and Hindi

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