Six Sigma Plant, Ceramic Engineering, Lean manufacturing

Azharuddin Mondal

****************@*****.***, 099********

B.Tech in Ceramic Technology

Govt. College of Engineering & Ceramic Technology - Kolkata

SUMMARY OF EXPERIENCE:

> Driving Cost saving projects via numerous Kaizen Events. Implement Lean

Tools like 5S, Glass Walls, Layered Audits, Standard Work Instructions

and Visual Management.

> Drive Yield Improvement Projects through Shainin and Six Sigma Tools.

> Lead Plant Productivity through Lean Implementation via Standard Work

and Visual Management to Takt Time

> Drive Plant Standards, by reducing BOM Errors and Routing Errors.

> Assist in creating plant Value Stream Mapping.

> Assist in Managing Fresh Graduate Engineers, with training Plan and

their Lean Journey

> Documenting Plant Savings, Kaizen Ideas, Plant Metrics in Lean.

> Conducting Reward Functions for Kaizen & 5S events.

> Handling a project to reduce crack through V-DEP (Vitreous Defect

Elimination Process)

> Handling Ceramic Cold Repair Project using Highly effective technology

from USA

> Giving training to employees on 5S, Kaizen, 8 Waste, Layered Audits.

> Certified in Six Sigma, 5S, Lean, Process Capability, Gage R&R(MSA),

FMEA

EMPLOYMENT DETAILS:

Senior Engineer (Quality and Continuous Improvement)

Kohler India Corp. Pvt. Ltd. Jhagadia, Bharuch, Gujarat

www.kohler.co.in, July 2012 - Till Date

. Handle Cost saving projects using Lean Principles and techniques.

. V-DEP (Vitreous Defect Elimination Process) Projects handling. Solved

Pinholes, Crack and Leak Projects.

. Kaizen Event organizing and continuous improvement of Kaizen systems.

. 5S facilitator. Continuously improving 5S culture of Kohler Company.

. Trainer of 5S and Kaizen System for all plant employees

. Assisting Capital Projects with their implementation plan.

. Present weekly Yield numbers to plant management, and support action

items.

. Tracking Cost saving and reporting them globally, supervise project

effectiveness

. Assist in generating department reports consisting of Quality &

Productivity sections.

ACHIEVEMENTS:

o Successfully developed new Kaizen system from January, 2014. Increased

awareness among employees and workers by organizing various events and at

the very first month we received more than 70 Kaizens.

o Collected total 658 number of ideas in 2014 and 98% of them were

implemented ideas. Generated savings in 2014- 1,72,65,372 Rupees

(275,000 USD)

o Successfully developed 7S (Sort, Set In order, Shine, Standardize,

Sustain, Safety and Savings) in Kohler Co.

o Successfully completed Two (2) V-DEP (Vitreous Defect Elimination

Process) projects in 2013.

1. Leak in Odeon: Previously leak percentage in this pattern was

7.2%. now it decreased to 2.8%

2. Pinhole in Windham: Previously Pinhole Percentage was 12%. now it

decreased to 7.5%

o Improved plant 5S culture via organizing 5S event throughout the

departments & training.

o Assisted in reducing Energy (saved 22,400 Rupees per month in cast

shop with modified systems).

PERSONAL CERTIFICATES

o V-DEP Front Line Leader

o Total (7) YAA (You Are Appreciated) cards from top management for

successful completion of different projects.

o 5S Practitioner certificate from 'The 5S Institute", Mumbai.

o Certified in FMEA & MSA from BVQI- Vadodara

o Six sigma Yellow Belt from MSME- Govt of India

KEY SKILLS

. Change Agent with employees and shop floor personnel

. 5S

. Kaizen

. Lean Standard Work

. Ceramics- Casting, Firing, Glaze & Slip preparations & testing,

Quality Functions.

Thanks for your time.

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