NITIN RAJURKAR

*** **, ***** *******, *********, Oregon 97006,

Cell 208-***-**** / 971-***-****, acxvt1@r.postjobfree.com

SENIOR MANAGEMENT EXECUTIVE

Manufacturing Engineering / Manufacturing Operations / Projects

Accomplished senior level executive with a 33 years track record of providing successful strategic, tactical and operations leadership within the automobile industry, in uniquely challenging situations.

CORE STRENGTHS AND SKILLS

Team Leadership Manufacturing Operations Body in White

Stamping /Tool and Die Lean manufacturing New Product Management

Kaizen / JIT / Kanban GD&T Robotics / Automation

World Class Manufacturing Program Management Simulations

PROFESSIONAL HISTORY

Tata Motors Ltd, Pune 2002 to 2014

(Senior General Manager / Program Manager / Operations Head)

Worked as Operation Head / Program Manager for various Divisions and in functions like Assembly and Manufacturing Operations, New Product Development, New Projects and Manufacturing engineering.

Headed Lean Manufacturing, capacity expansion and Productivity improvement initiatives. Responsible for Jaguar Land rover India Assembly Operations, in setting up of plant and Operations post start up.

Head of Operation Management of Modern Press shop and robotic Welding shop, with 2000 operatives and 100+ White collars. Stamping process involved ‘Class A’ Skin panel Stamping for Passenger cars, on 3 Fully Automated Tandem Lines, Blanking line and a flexible BIW Weld line and Closer Hemming line with 300+ robots. The role involved Daily work management DWM, review daily bottlenecks and deliver as per SQDCME targets, improve Quality, Cost and Safety parameters.

In charge for Project and Program Management of Passenger car line products. Responsible for facility project for introduction of 4 new models ‘Vista’, ‘Manza’, ‘Bolt’ and ‘Zest’, with complex facility automation in various shops, launched 10 short term programs and 4 mid-term programs in span of 3 years. Responsible for sourcing of Stamping dies and BIW Weld line, including Closer Hemming lines for 6 Full vehicle programs, from World Class Tool Rooms from Japan, Korea, China, Thailand, Taiwan, India, Spain, Italy, Germany. Visited Stamping shops in Europe, Korea, China, Japan for the Best Practice benchmarking from Ford, VW, Opel, Skoda, Mercedes, Audi, Hyundai, Nissan, Fiat, Renault.

Worked, as leader of Simultaneous Engineering team on 4 major programs from the stage of Styling, Clay, Feasibility stage, upto Tools / Facility planning, implementation and start up stage. Led Digital Manufacturing program to implement new model introduction on current lines as well as for Green field programs. Reduced Capital cost, Optimized payout, Improved logistics flow, Reduced Manpower, Reduced Weld gun variety, Reduce waste time of Robots by optimizing paths.

Head of Manufacturing Engineering team responsible for Stamping shop, BIW Weld shop, Paint shop, Vehicle Assembly shop, Power train shop as well as Logistics planning, Utilities planning.

Champion for ‘Deming Policy’ initiative with Cross Functional Team on cost reduction, waste elimination and reduced operation cost by about 15%. Implemented ‘World Class Manufacturing’ (WCM) concepts for driving ‘Continuous improvements’ and ‘Employee Involvement’. Responsible for Capacity expansion of plant from 500 to 1000 Units per day, by introducing technologies to improve quality, cost and cycle time.

Mahindra & Mahindra Ltd, Mumbai 1994 – 2002

(Deputy General Manager)

Head of Manufacturing Engineering Division, responsible for implementation of new vehicle program ‘Scorpio’, ‘Armada Pickup’ ‘Voyager Van’ with technology transfer program in setting up of modern Stamping shop and automated flexible Weld shops. This program was initially co-developed with Ford, hence involved a major learning on GPDS Global Product Development System, APQP and PPAP. Led Sourcing of Stamping dies for Class A and Inner Structural panels and BIW Weld lines, Closer lines for 6 Full Vehicle programs from various sources from Japan, Korea, Thailand, Taiwan, and South Africa.

Planned and commissioned a modern Tool and Die Making shop, with Technical Collaboration with Fuji Technica, Japan, with High Speed Machining Centers, with 24X7 running capability. It is the most modern and most efficient Die shop in India, even today. Planned support processes like CAD / CAM, Die Design, Pattern making, Checking fixture making etc

Program Manager for introduction of 4 vehicles in span of 4 years, with technology support from Japan and Korea. Visited Vehicle Assembly plants in Korea, Germany, South Africa, Thailand, UK and Australia to benchmark the Best Practices from Ford, GM, Hyundai, Honda, Daewoo, Samcor, and Mercedes.

Responsible for major program for Business Process improvement. Brought focus on Capacity rationalization, Waste reduction, Quality improvement, with major layout changes, by bringing modern facility, process automation, pokayoke and training in Assembly shop and BIW Weld shop. Supported Mahindra Ford JV program for CKD assembly of a car, with new BIW Weld shop, new Assembly shop and Warehouse. This involves major training with Ford under Ford Production System FPS.

Maruti Suzuki, Gurgaon 1988 – 1994

(Deputy Manager)

Manufacturing Engineering activities for Stamping shop and Welding shop for 3 model programs. New Projects, JV Supplier development. Provided Manufacturing Engineering support to Operations team to implement Lean Manufacturing techniques like Pokayoke, Kanban, JIT/ JIS, Hiejunka and Yamazumi. Played key role in setting up facility program of High Speed automated press shop and Weld shop including Cross Bar Transfer press, Tri Axis transfer press and Fully Automated Tandem line and Robotic BIW weld lines, including Closer Hemming lines.

Worked as Champion for component development / localization of @ Structural inner 50 parts, leading to a major cost reduction. Was a Leader for a program for Supplier part quality improvement for 12 suppliers. Improved their supplier rating parameters, by working with them on tool and equipment maintenance, tool and process design. Visited Korea, Thailand and Japan for Tooling sourcing.

Planned and Set up a Die making shop for Structural inner panels to start with, which was demonstrated to deliver good quality results, hence got approval to expand that Die shop for making Class A Stamping dies as well. Trained Die Process Planning and Design team personally.

Premier Automobile Ltd, Mumbai 1981 – 1988

(Senior Engineer)

Worked as Tool and Die designer, Tool manufacturing, and Tool try out. Played key role in execution of 118NE car program, by localization of key dies and BIW weld line fixtures with substantial cost saving. Commissioned and Tryout of Class A and Structural inner panel dies for Passenger car. Local design and manufacturing of Stamping dies and Welding fixtures for 30 Structural inner parts.

My Strengths

Excellent communication skills, excellent analytical, problem-solving, negotiation and organizational skills.

Demonstrated experience working on complex plant engineering and capital projects. Strong understanding of engineering principles and practices.

Decision making abilities to successfully direct concurrent projects. Strong adherence to processes and initiate process improvements as needed. Ability to work on complex issues where analysis situations or data requires an in-depth evaluation

PROFESSIONAL DEVELOPMENT

Michigan Ross School of Management – Senior Executive Management training

Mumbai University – Post Graduate Diploma in Business Management with ‘A Grade’ in year 1987

Walchand College of Engineering – Bachelor of Mechanical Engineering with Distinction in year 1981

Tata Senior Executive Leadership training, Tata Business Excellence Model

Managerial Effectiveness Courses – SQDSME, Leadership, Problem solving techniques, Cost Management, Negotiation skills, Finance for Non-finance

Operation Excellence – World Class Manufacturing, Lean Manufacturing techniques. TQM

Technical training – DFMEA, PFMEA, GD&T, Six Sigma, SPC

Quality Operating Systems – Deming, TS16949, ISO9001, ISO14001, OSHAS, SA8000

COMPUTER EXPERTISE

SAP, MS Project, MS Office programs, Delmia (Digital Manufacturing), PLM, Simulation. MES

AWARDS AND RECOGNITIONS

Invited by VDMA for presenting paper on ‘Robotics and Automation’ at Hanover, Germany

Made presentation at Tokyo, Japan about ‘Digital Manufacturing’

Made presentations in AMS International forums (Shanghai, Chennai, Mumbai, and Pune).

Invited by CII, Bangalore, IIT, Delhi and IIT, Mumbai for presentation of papers about ‘Latest trends in manufacturing technologies in automobile industry.’

Regularly featuring articles A&D Magazine, AMS Magazine and recognized as ‘Pioneer of Automation in Indian Automobile Industry’ by A&D Magazine.

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