Plant Maintenance

Seeking assignments in:

~ Production ~ Maintenance ~ Marketing ~QA~QC~ New Product Development~

Industry Preference: Automatic Iron Foundry

Domain Expertise: HPML / Fully Automatic Ductile Iron, Gray Cast Iron Foundry, Automotive Sector; Non-Automotive; Railway & Power Transmission

PROFILE SUMMARY

A VSME Graduate with 14+ years of pioneering experience in Production, NPD, Marketing,

Expertise in managing business operations involving resource / production / materials planning, in-process inspection, team building, design & development and co-ordination with internal & external customers

Abilities in enhancing production process operations, optimizing resource and capacity utilization, escalating productivity and operational efficiencies

Proficient in implementing cost saving measures to achieve substantial reduction in cost of production, raw materials, manpower & machine

Possess production & development experience for casting of Daimler, Dana, Honda, M&M, Spicer, Arvin Meritor, ZF, Bonfiglioli, Carraro, Haldex, Sona Koyo, Iljin Auto, Bosch, Emerson, Knorr Bremse, Eaton, Bharatbenz (Approx. 1500T/M)

Comprehensive knowledge of quality standards like Kaizen, 5S, TPM,MBF and various tools & technology; proficient with Magma Simulation, Zircast & Soft Cast

Travelled to Japan for commissioning/technical training of KOYO 60 VS high pressure flask less moulding line & made official visit to Hannovermessa (Germany) for new business development

Holds the merit of successfully completing audits more than 100 customer audits in past 14 years

Excellent interpersonal, communication, team building & customer relationship management skills with ability to relate to people at all levels in the organisation

AREAS OF EXPERTISE

Production Planning & Control: Overseeing production related tasks including planning, control and troubleshooting. Setting up production targets and achieving the same within time and cost parameters. Supporting production activities by way of setting up new manufacturing processes, proving new machines, jigs, fixtures, tooling etc.

New Product Development: Monitoring development of products with respect to cost, resource deployment, time over-runs and quality compliance; evaluating production progress & taking adequate corrective actions. Organising, planning and coordinating the entire product development including requirement analysis, finalising parts specifications, designing, verification & validation, etc.

Preventive Maintenance: Managing routine maintenance / preventive maintenance schedule and calibration for production equipment on a regular basis for higher productivity and efficiency. Analysing various processes / applications and recommending process modifications and equipment calibrations to enhance operational efficiency.

Quality / Process Improvement: Managing/Planning and organising day-to-day shop floor activities and resolving procedural & logistical problems as appropriate to the timely completion of various processes. Formulating SOP for new processes/ equipment for ensuring environment, health & safety aspects. Submitting periodical reports of quality indices to senior management.

Cost Reductions: Handling various continuous improvement initiatives in the process. Conceptualizing & implementing strict measures in operating various procedures to optimize resource as well as capacity utilisation. Maintaining High Operator Morale by involving them in TPM activities. Reducing the cost by implementing Kaizen.

Shop Floor Operations: Monitoring sample production processes, conducting root cause analysis tracking the defects and taking corrective action. Scrutinizing process & field parameter of equipment to ensure adherence to standards by conducting periodic audits.

Man Management: Effectively interfacing with people at all levels, managing healthy work environment & inculcating bonded teamwork with high work ethics. Mentoring subordinates & maintaining cordial relations

CAREER ACCOMPLISHMENTS

Headed the complete plant uplift from take over at closure to full capacity production 600 T/M – Tulsi Foundry Sangli

Successfully led installation of KOYO SM 60 vs. High Pressure Vertical Flaskless Moulding Plant with installed capacity of 1500T/M

Acknowledged for developing new products on KOYO (Auto Core Setting Tool)

Attained 1250t good casting on KOYO line

Holds the merit of implementing TS & ISO 1400

New Business Development for Honda, Eaton, American Axles, Emerson, Daimler, Bosch, ZF, Carraro India etc.

Led VSME Graduation by Anand Group which involved implementation of operation excellency

Pivotal in installing DISA 32 X 32 MATCH flask less moulding plant with installed capacity of 2500 T/M

Significantly contributed in development of 570 T/M load within 2 years for Spicer India, DANA, Carraro, etc.

Catalyst for installation of DISA & EIRICH Sand Mixer, Sand Cooler (DISA COOL), CRCA Bailing Plant, Civil Constructions Activities, Shot Blasting Machines, Wedge Cutting Machine, etc.

Demonstrated excellence in installing On Line Shot Blasting System with capacity of 12T/Hr

Enhanced the melting capacity by installation of try track 2t furnaces

Stellar role in installing CNC & VMC setup for Machining & Pattern Shop

ORGANIZATIONAL EXPERIENCE

Since 15Aug: Alucast auto components (AAC),Belgam as GM- Foundry.

Manufacturer & supplier of SG Iron Castings and machined components, with High Pressure Horizontal Flask less Disa 130 line / Omega Line. Installed capacity is 2000T/M.

Since Nov’13-15Aug Vishal Manufacturing Pvt. (VMPL), Rajkot as GM- Operations

Manufacturer & supplier of SG Iron Castings and machined components, with High Pressure Horizontal Flask less SINTO line / Omega Line. Installed capacity is 2500T/M.

Key Result Areas

Accountable for heading the complete production operations

Functioning as a Management Representative for Customer Relations

Conceptualising parameters to generate maximum operational efficiency

Highlights

Pivotal in developing 24 parts (automotive & non-automotive) in nine months and executed cost reduction project

Holds the merit of enhancing the production rate of HPML line by process & equipment fine tuning, core setting time, filter setting, etc. (For sinto HPML capacity 200m/hr achieved 180m/hr non cored achieved & 125m/hr for cored)

Got acknowledge for increasing the production from 125 M. Tons to 780 M. Tons in last 12 months

Recorded an improvement in productivity through multi-cavity concept for Moulding Patterns & Core Boxes

Successfully implemented CALPOUR and HD Sleeves, Chills in Auto-Mode Moulding

Played a key role in improving the quality of the product by reducing in house rejection 22% by implementing MBF tool

Instrumental role in taking several measures to identify deformities, malfunctions or any type of abnormalities in parts / components / products

Pivotal role in reducing the rejection rate by 6% in house 2% at costumer end.

Oct’10-Nov’13: Tulsi Casting and Machining Ltd., Sangli as GM –Production

. An ISO/TS 16949 certified company manufacturer & supplier of SG Iron Castings and Machined Components with High Pressure Vertical & Horizontal Flaskless DISA line /Koyo Line / CNC –VMC setup. Installed capacity is 4500T/M.

Key Result Areas

Guided the project teams and integrated their efforts to maximize operational productivity

Significantly contributed in developing need based jigs/fixtures/tooling/dies/test equipment

Highlights

Demonstrated excellence in:

oInstallation of DISA 32 X 32 MATCH flask less molding plant capacity of 2500 T/M

oCapacity improvement of melting capacity by installation of tri track 2 T Furnace

oImproving productivity in vertical & horizontal line

oLeading On-Line Shot Blasting Installation and Online Fettling Cell Development

oCarrying out online inspection

oDeveloping 600t new load on match line

oIntroducing HD sleeves increasing yield by 15% to 20 %

oMatch machine run at 99 m/h(machine rated 100m/h)

oDeveloping Multi-Cavity Core Box for core production enhancement

oStreamlining operations of core setting and implementing POKAYOKE for process control

oImproving in yield by 6% to 7% on vertical line

May’09-Sep’10: C.M. Smith & Sons Ltd., Ahmedabad. As Plant Head

An ISO/TS 16949- Manufacturer of SG Iron & Cast Iron Casting for Automotive & Non-Automotive Industry with high pressure Fritz Hansberg S.P.A Horizontal Flask Moulding Line. Installed capacity is 1500T/M

Key Result Areas

Managed development of S.G. Iron using automatic pouring online

Contributed in designing castings & core related fixtures

Carried out trials to identify deviations, thus making relevant modifications in pattern to stabilize the product

Highlights

Successfully developed Eaton Gear Case, S.G. Iron Hub, Brake Wheel Hub, Brake Drum and G.B. Front & Rear (TATA)

Led core setting tool for heavy core setting on line

Pivotal in executing cost reduction project by doing hollow core in several items

Developed Auto Core Setting Equipment for Gear Boxes and Transmission Case

Holds the merit of enhancing the production rate of HPML line by process & equipment fine tuning

Increased the production from 300 M. Tons to 650 M. Tons in last three months

Successfully implemented CALPOUR and led 4 MT FOMET Press Pour installation

Dec’04-May’09: Tulsi Foundries Ltd., Sangli as Project and Production Head

An ISO/TS 16949 Manufacturer & Supplier of SG Iron Castings and machined components manufacturing with high pressure Disa 2110 MK line /Koyo Line / CNC –VMC setup. It has an installed capacity- 2500 T/M

Key Result Areas

Headed the overall production and quality operations

Effectively executed various projects and led plant engineering activities

Designed core related fixtures and successfully implemented POKAYOKE for process control

Served as an Internal Auditor as per TS & VDA6.2

Acquired all environment related approvals

Highlights

Essayed a stellar role in:

oReconditioning of DISA 2110 line after three years of stoppage

oIntroduction of new pouring system and replacing old one thereby eliminating 35% of Break down time.

oDevelopment of new vibratory knock out replacing vibro - conveyor & rotating drum

oImprovement of Sand Conveyor System to prevent maintenance delays

oDevelopments of polygon sever installation of TM 160 disa sand mixer in sand plant

oInstallation of dual track medium freq induction furnace of 2 MT * 2 nos

oImproving Furnace charging system replacing old one

oImproving shot-blasting capacity by installing VP 140 Hangar type shot blasting machine –DISA

oImproving core shop capacity by reconditioning / overhauling of core making machines (Compax core shooter)

oEnhancing new material handling equipment and overhead casting cooling conveyor

oPerforming general maintenance (preventive/predictive/productive).

oExecuting projects such as installations of NEW KOYO 60 V S HI Pressure Vertical Flaskless Moulding, Plant, Sand Mixer, sand cooler (DISA COOL), CRCA Bailing plant, civil constructions activities, shot blasting machines, wedge cutting machine

oInteractions with Foreign delegates / dealing of maintenance spares/ party

PREVIOUS EXPERIENCE

2002-2004: Tecnocrats & Concord Marketing as Director

EDUCATION

Bachelor of Foundry technology

VSME Graduate – Operations Excellency (Spicer India)

Diploma in Mechanical Engineering

PERSONAL DETAILS

Date of Birth: 26th December, 1979

Linguistic Abilities: English, Hindi, Gujarati and Marathi.

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