Production Management:Welding & Fabrication its automation

Firoz Khan

Production Management : Welding and Fabrication

Manufacturing Automation : Robots, Mechanized machines and Fixtures.

Email: *****.********@*****.** DOB : 08/12/1977

Address: SF40B, Texmaco Estate, Kolkata, W.Bengal, India Contact No.: 987-***-**** Passport No. – M4846574

PROFESSIONAL SYNOPSIS

A technically qualified professional with over 14 years of experience in Shop Floor Operations (Welding & Fabrication), Process Improvement, Strategic Planning and team management.

Working in Texmaco Rail and Engineering Ltd. as Manager from July’12 onwards, expertise in Production Management and Manufacturing Automation (robots and mechanized machines) in the fabrication shop. Includes, hands on knowledge of Robotic Weld Shop for complete project setup (planning, negotiations, installation, commissioning, programming) and responsible for both operational & preventive maintenance of welding/cutting robots. Certification of Welding Coordinator as International Welding Technologist.

Seeking senior level assignments in Shop Floor Operations and Process Enhancement (Welding and Fabrication) in a Manufacturing Industry engaged in production or project implementation.

KEY COMPETENCIES AND SKILLS

New Project Planning/setup Production Management Welding Robots Programming

Safety /Preventive Maintenance Manufacturing Automation Fabrication/Assembly/Welding

Quality Control /Inspection TPM, 5S, Kaizen Process Improvement

WORK EXPERIENCE

1 - Summary of Experience in Texmaco Rail & Engineering Ltd. - Kolkata, West Bengal

Role: – Manager (Mechanization & Robotics) (July’12 till Date)

Company Profile:

Texmaco Rail & Engineering Limited is an ISO: 9001-2008 Company, the largest freight wagon builder in the private sector. It is the market leader in railway wagon manufacturing in India.

Role Context:

I am responsible for Production management and manufacturing automation in fabrication.

Production management - Planning, coordination and control of manufacturing processes in fabrication (welding, cutting and assembly).

Manufacturing automation - Setting up of New Projects for process improvement, which includes planning and installation (Robots, mechanized machines & fixtures).

Roles & Responsibilities:

Production Management

Planning and controlling the productions of wagon components based on schedules and organize resources (man, machine, material) accordingly.

Responsible for achieving Welding & Fabrication Shop Production targets

Minimizing performance bottlenecks for achieving high productivity by Optimization of Resource utilization.

Liaising with various departments to ensure uninterrupted operation in production.

Process Improvement

To ensure that the production is cost effective by Introducing innovative manufacturing processes, increasing the overall equipment efficiency (OEE) and monitoring cost of critical consumables by implementation of KAIZEN, PRIDE and TPM etc.

Identifying machines & equipment (Robots, Mechanized machines and fixtures) required for process improvement, there selection, negotiations, installation & commissioning.

Other Activities

Trained personnel on Programming of welding/cutting robots (CLOOS, FANUC, IGM, KUKA).

Identifying the training needs of Welders, Fabricators and Operators to enhance productivity.

Maintaining and scheduling Preventive Maintenance (PM) of critical machines through CLITA.

Coordinating and troubleshooting maintenance issues of Robot machines and equipments.

Contacting OEM, integrators, suppliers for purchase of machinery, spares and consumables.

Projects Coordinated (Installation of Equipment/fixtures related to Welding and cutting automation):

Setting-up and commissioning of plant machineries/ equipments/ Accessories of the Fabrication Welding Shop. (Robots, mechanized m/c, fixtures, power source, torches, etc.)

Installation of IGM and KUKA Robot systems for welding and cutting.(single and twin system)

Installation of GULLCO & KOIKE tractor, mechanized m/c – welding (MIG/TIG/SAW) & cutting.

Installation of Hydraulic and pneumatic fixtures for wagon components.

Installation of automatic positioner-type manipulator to be used for welding/assembly.

2 - Summary of Experience in TATA-HITACHI – Jamshedpur; Jharkhand

Role: – Engineer (Production) (Aug’05 to June’12)

Company Profile:

TATA-HITACHI -(60:40 Joint ventures of Hitachi Construction Machinery and Tata Motors) India’s largest construction equipment Manufacturer. (Product: Excavator, Wheel Loader, Crane etc.)

Role Context:

Supervision of fabrication (assembly, welding and dressing) of excavators, wheel loaders, cranes.

Supervision and hands on experience in operation and programming of MIG welding robots (CLOOS, FANUC, IGM) and increase it’s OEE.

Roles & Responsibilities:

Plan and schedule the daily production of boom, arm and bucket of Excavators and cranes and ensure its achievement. (series Ex-120, 200, 350, 1200 and ZX-210, 450, 650)

Programming and Operation of IGM, CLOOS, FANUC Welding Robots and increase it’s OEE.

Conducted numerous process improvement activities in the form of KAIZEN Presentations.

Leading a team and responsible for their productive output for fabrication, welding & dressing.

Working as Independent Shift Incharge focusing towards minimizing assembly line Stoppages.

Interpreted welding defects through various inspection tests in UT, DPT.

Involved in in-house and vendor material quality self check and inform to Q.A.

Actively involved in TPM & 5S implementation which resulted in decreased M/C downtime.

Plan and prioritize own work load along with team members work load.

Knowledge of welding defects (interpreted during inspection tests UT and DPT), processes, and reduction of distortion levels during fabrication to carry out the job effectively.

Maintaining welder’s competency records as per their skill development.

100% Self inspection of job before move to next customer.

3 - Summary of Experience in Tata Motors – Jamshedpur, Jharkhand

Role: – Junior Engineer (Cab and Cowl) (April ’01 to Jul ’05)

Company Profile:

Tata Motors Limited is an Indian multinational automotive manufacturing company in India. Its products include passenger cars, trucks and buses etc. exported to over 165 countries.

Role Context:

Experience of supervising assembly line of body shops involved in fabrication of cab/cowl of busses and trucks of different models like -Lorry for Passenger (LP), Semi Forward Cowl (SFC), 2516/3516 cab, 1109/909/407 cab out of a total of 1200 types of vehicle fabricated.

Roles & Responsibilities:

Supervision of man, material and machine as per the daily production requirement and report any abnormalities/shortage to seniors.

Ensuring that the daily production target is achieved and any deviation from normal was to be informed along with maintaining in the logbook.

Ensure all tasks are completed to the required set standard and any defect by QA in quality found in finished cab/cowl is to be reworked.

Taking initiative for cost control by saving power consumption, compressed air during non working hours of the day.

Tracking of PPE of operators and SOP for all the Operations to avoid any accident.

Provide on job and theoretical training to technicians/trainees as per the job requirement.

Imparted practical and theoretical training in welding processes.

TRAINING

HHH (Hitachi Hand Holding) training for quality & process improvement in Fabrication shop.

Training in Tata Motors in cab and cowl fabrication shop.

Robot Operation and Programming with Arc Tool/gripper by KUKA India Pvt. Ltd.

KUKA, IGM, CLOOS and FANUC Welding Robots on the job programming/operation training.

TPM, 5S, Kaizen training.

Safety and first aid training in the safety division of Tata Motors.

CERTIFICATIONS

Certification of International Welding Technologist (IWT) from International Institute of Welding (ISO 14731) - diploma no.-in/iwt/51000291. [IWT have greater in depth technical knowledge and expertise to undertake work of the responsibility of weld design, selection of process & procedure for fabrication with safety and can take responsibility as Welding Coordinator in a manufacturing industry.]

Certification of competence as a Robotic and Mechanization Engineer from Australian Welding Services (WA) - reference no. - ABN 32-163-***-***.

QUALIFICATION

ACADEMIC QUALIFICATION

2010 EMBA (Operations Management) from ISBM.

2008 B.E. (Mechanical Engineering) from the Institution of Engineers (India).

1998 Diploma in Mechanical Engineering.

1994 Schooling from Gulmohur High School, Jamshedpur affiliated to ICSE.

IT FORTE

Computer literate and knowledge in different computer programs such as MS Office Application, Excel, PowerPoint, SAP. Diploma in Office Computing from ZED Career Academy.

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