Key Skills

Project Management

Facility Planning

Layout Planning

Logistics Planning

Capacity Planning

Capex

Costing Budgeting

Lean Manufacturing

Inventory Management

Total Preventive Maintenance

Quality Management

2D & 3D Design

Lean Six Sigma Green Belt

Kaizen Waste Management

Team Management

Soft Skills

Seasoned & innovative Manufacturing Engineer with 21+ years of experience in planning, developing & implementing manufacturing, assembly & logistics processes in top notch engineering & automobile companies.

Demonstrated success in introducing new products for production, developing, implementing and managing new processes to improve quality & productivity. Hands-on experience in fabrication, machining, assembly and lean manufacturing with excellent creative, analytical, problem-solving & team-building skills. Process-driven and compliance-oriented with expertise in leading, training & motivating cross-functional teams to exceed defined goals. Career Timeline

Work Experience

Kirloskar Pneumatic Company Ltd.

Company manufacturing engineering products including air compressors, air conditioners, refrigeration systems, process gas systems, vapor-absorption chillers and industrial gearboxes

Sr Manager (Manufacturing Projects) - Aug 2021 to Present Drive Project with respect to SQDCME Pillars

Coordination and closely working with internal & External stakeholders Prepare and submit budgets, project plans, and reviews for monitoring, reporting and approvals with stakeholders

Understand and use Theory of Constraints to improve performance; reduce time at bottleneck

Manager (Manufacturing & Industrial Engineering) - Aug 2017 to Aug 2019 Day-to-day operations of a Greenfield Plant Project for the air compressors division of the company.

Initiate & implement facility planning for the Assembly, Dispatch & Foundry to ensure smooth movement of raw materials and finished goods. Supervise Capex for the entire project based on techno-commercial requirements, preparing the budget and justifying it based on the payback period and costing. Innovation

Communicator

Problem Solver

Collaboration

Negotiator

Planner

PG – IIT KGP +

Research Fellow

(Department of

Science and

Technology)

Rushikesh Tawade

ad3fky@r.postjobfree.com +91-797*******

‘01-’04 ’04- ‘06 ’17 - ‘till date

Transmission

Planner (Tata

Motors Ltd.)

’99- ‘00

Trainee

Engineer

(Mukund

Flexpack Ltd.)

Sr Manager

Manufacturing

Engineering

(Tata Motors

’06- ‘07 Ltd.)

Asst Manager

Manufacturing

Engineering (Bharat

Forge Ltd.)

’07- ‘12 ’12- ‘17

Deputy Manager

Process Planning

(Walchandnagar

Industries Ltd.)

Sr Manager

(Kirloskar

Pneumatic

Company Ltd.)

Tata Motors Ltd., Pune

Indian multinational automotive company manufacturing passenger cars, trucks, vans, coaches, buses, sports cars, construction equipment and military vehicles

Manufacturing Engineer (Vehicle Assembly Line) - Jul 2012 to Aug 2017 Handled the assembly lines & stores, planning the layout, capacity & capex, procuring plant machinery, establishing the manufacturing equipment and designing strategy for inventory norms at line-side/supermarket/store for Tata Sumo & Tata Xenon vehicles.

Cut down costs by (i) reducing wastage through lean material flow & lean manufacturing, (ii) utilizing Design for Manufacturing (DFM) process and (iii) planning & implementing 2-bin system, Kitting, Kanban scheduling system & just-in- time manufacturing.

Optimized manpower planning through Kaizen & MOST exercises, forming cross-functional teams for product improvement and for planning & execution of WCQ (world-class-Quality) standards. Improved in-house processes & quality, executing projects to reduce scrap, enhance productivity/overall equipment effectiveness (OEE) and through material-handling systems & storage arrangements Coordinated with Supply Chain & Production teams to improve the design for packaging of parts, also evolving the methodology & strategy for logistics of new-variants parts. Implemented & maintained work standards, regularly demonstrating new & existing equipment to systems engineers, support staff & production managers.

Eliminated processes that are non-value-adding, scrap-generating and environmentally hazardous. Documented the Process Flow Diagrams (PFD), control plans, Process Failure Mode Effects Analysis ((PFMEA), stage drawings and process sheets.

Planner (Transmission) - Sep 2007 to Jul 2012

Spearheaded the project planning & process planning for new transmissions & BS-IV gearbox including PFMEA to identify & evaluate potential failures of a process in DELMIA software. Handled the Facility Planning, Layout Planning, Cell Formation, Product Delivery, Capacity Planning and Capex enquiries for increasing volume of production or manufacture of new products. Developed the tooling concept, selected machines & planned man-power in New Product Development, coordinating between Design, Product Programming, Material, Production & Quality Assurance teams to develop SOPs & deliver prototype/product.

Enhanced productivity & reduced cycle-time by implementation of Kaizen & Kitting and initiating new tooling concepts, working with designs to develop the tools.

Involved the team in product-design reviews done internally & with customer representatives, building team-work & morale, also coordinating many employee-initiatives.

Achievements:

Achieved one-time cost-savings of Rs. 4 Crores by merging 3 separate assembly lines for 'Sumo' and 'Xenon' vehicles into 1 as Manufacturing Engineer.

Minimized production losses from 40% to 4% by ensuring continuous availability of parts during manufacturing through the implementation of Kitting & Supermarket System for all vehicle assembly lines as Manufacturing Engineer. Designed the complete logistics & layout plan for the assembly of Xenon Yodha, Hexa, as Manufacturing Engineer. Achieved space-creation in the G550 & G85 Gearbox through layout plan & set-up execution as Planner. Reduced cost by over Rs. 27 Lakhs through various cost reduction programmes as Planner. Bharat Forge Ltd., Mandhwa, Pune

Indian multinational company involved in automotive, power, oil & gas, construction & mining, locomotive, marine and aerospace industries

Manufacturing Engineer - Jul 2006 to Sep 2007

Contributed to the process development & regularization for Crankshaft, Beam & Knuckle products through the Machining/Grinding processes.

Handled the entire process planning, tooling design (jig/fixture using AutoCAD/Proe WildFire), selection of machining/cutting tools along with parameters/sequence and technical documentation (PFA/PPAP/FMEA/Process Sheets/MQP).

Achievements:

Developed the 3-Lit & 5-Lit Crankshaft also ensuring the complete documentation of Production Part Approval Process

(PPAP)

Walchandnagar Industries Ltd., Pune

Heavy engineering products and EPC services company known for pioneering achievements in Indian engineering industry and for its contribution to nation-building activities

Deputy Manager (Process Planning) - Jul 2004 to Jul 2006 Planned & executed unique job-oriented projects of the Central Government that included building ship & satellite parts through special manufacturing set-up.

Collaborated with scientists & auditors to get approval for manufacturing documents. Achievements:

Achieved approval for all the process documentation of defense project from BARC & ISRO. Department of Science and Technology (DST)

A department within the Ministry of Science and Technology in India Research Fellow - Dec 2001 to May 2004

Worked on project for Titanium machining using cryogenic cooling, modeling the Nozzle and handling all machining operations.

Mukund Flexpack Ltd.

Trainee Engineer - Dec 1999 to Aug 2000

Supervised the day-to-day production activities, assigning labour, ensuring quality & documenting production reports. Education & Training

Master of Science (Mechanical Engineering) with 8.97 CGPA, IIT Kharagpur, (2002-04) Project - “Role of cryogenic cooling on machinability of Titanium alloys (Ti-6Al-4V) in Endmilling”. This DST-sponsored project was experimented and studied for the development in machinability for the applications of Aerospace Products Ti-6Al- BE (Production) with distinction, SRTM University, Nanded (1995-99) Project - "Automatic Crop Cutting Machine". This is an advanced agricultural project. The mechanism of machine is based upon the transmitting motion by worm & worm gear and powered by diesel engine. Lean Six Sigma Green Belt (May2023)

One-month industrial training in “Vanaz Engineers Limited”, Pune. Four-month training course in ProE2000i in “Pentasoft Communication Ltd.”, Pune Proficiency in AUTOCAD, DELMIA, MS Office & Internet Applications. Publications:

International journal in “IMECHE, part B, Journal of Engineering Manufacturer, “Turning of titanium alloy under cryogenic cooling by TiB2 coated carbide tool”

21st AIMTDR conference, “Role of cryogenic cooling on machinability of Ti-6Al-4V in end milling”. Personal Details

Linkedin ID : https://www.linkedin.com/in/rushikesh-tawade-94432871 Date of Birth: 25 th May 1978

Gender: Male

Family Status: Married

Address : Flat No. - 305, Lkshmi-Bhakti Hos. Society, Survey No.44, Rahatani, Pimple Soudagar, Pune - 411017 (Maharashtra)

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