Umesh Kumar Dhatwalia

Mobile: +91-981******* ~ +91-941*******

E-Mail: adbpio@r.postjobfree.com ~ adbpio@r.postjobfree.com

Manufacturing~ Production Management~ Production Planning~ Quality Control~ Process & Quality Improvement ~ Resource Optimization~ Maintenance~ MIS~ Purchasing~ Liasoning~ Budget Control

Location Preference: Himachal Pradesh, Punjab, Delhi/NCR, Chandigarh, Haryana, Uttaranchal

PROFESSIONAL ABRIDGEMENT

µA multifaceted manufacturing professional with 20 years of experience in managing the overall production operations from planning to execution.

µExpertise in handling the production operations, conceptualizing and implementing measures for enhancing operational efficiency and productivity.

µHands-on experience in Production planning, scheduling, Quality Control, Manpower and Shop Floor Management, Inventory Management, Operations and Maintenance, Capacity Planning, Line Balancing, Process Setup & Validation, Rolling, Punching, Flame Hardening, Pre-treatment (Phosphating), Painting, Adhesive Coating, Rubber Molding, Fabrication and Assembly.

µWell versed with TQM, TPM and Lean Manufacturing Concepts for productivity and quality improvement, waste and cost reduction. Sound exposure to concepts like, 5S, kaizen, Quality Circle, Standard Work, SMED and Autonomous Maintenance etc.; sound knowledge of QMS ISO 9001:2015/ TS 16949, EMS, OHSAS and ERP/SAP. Certified Internal Auditor for ISO 9001.

µProven leadership skills involving managing, developing and motivating teams to achieve their production objectives.

µDemonstrated communication and relationship management skills with the ability to lead and work in cross-functional teams.

µExcellent computer and analytical skills.

CORE COMPETENCIES

Production Planning & Control

ÄOverseeing the production and procurement policies, procedures and related requirement in line with internal controls and ensuring compliance with quality audits requirements.

ÄLooking after design, development and implementation of programs and procedures to maximize production, minimizes waste, increase capacity and efficiencies.

ÄEnsure Capacity planning; line balancing, process layout and incorporating FMEA key factors in planning to avoid failures.

ÄEnsuring timely execution of planned activities to meet the delivery schedules.

Quality Management

ÄEnsuring effective implementation of QMS and EMS under ISO and OHSAS certification; implementing lean techniques / process control measures to ensure better quality in all products.

ÄMeeting the set quality objective by analyzing the data for continuous improvement and achieving the company objectives.

Process Setup, Validation and Improvement

ÄEstablish process for new products and validate before going to mass production.

ÄRecommending modification / design changes in the product based on customer feedback through field service complaint.

ÄImplementing process control measures to ensure better quality in all the products.

People Management

ÄDeveloping, managing and monitoring the performance of a multi-skilled work force inclusive of production, planning and maintenance personnel.

ÄConceptualizing need-based training programmes for the officers and the operator workforce.

Budget Control

ÄMonitoring of fund flow to ensure smooth functioning of plant.

ÄEnsuring availability of sufficient funds for vendor payments and other overheads.

ÄFocusing on reducing overheads without affecting the quality of product, safety and legal requirements.

CAREER CONTOUR

M/s CLG Exports Limited, Amroha (UP) Aug’19- till date

As Assistant General Manager- Production & Quality

ÄUnderstanding the customer requirements from the samples and ensure properly converting into PFDs’ Control Plans, and finally getting the samples approved from the customers before mass production.

ÄDecision for in-house production or outsourcing to vendors. Ensuring availability of raw material and other inputs to avoid delay in manufacturing delivery of products.

ÄEnsuring product quality in the semi-finished components from vendors as per the customer requirements through SQA team.

ÄManage team of process managers and QAs from fabrication, polishing, Phosphating, powder coating, lacquer coating and final packing lines.

ÄEnsuring execution of production plans as per schedule to ensure on time delivery to customers.

ÄEnsure compliance to quality control systems; steering strict observance of specified procedures to intercept materials at early stage for rectifications.

ÄMonitoring customer/ third party inspections, customer complaints, performing root cause analysis and closure of the issue with proper CAPA plan.

ÄMonitoring the rejection trend and take appropriate actions to prevent or lower down the defects. Sharing monthly MIS to the management for review.

ÄDrive improvement activities like Kaizens, IPVs, Jig-Fixtures validation to ensure continuous improvement and involvement of team.

M/s Budget Signs, Baddi Feb’19- Aug 2019

As Production Head

ÄResponsible for execution of production as per schedule to ensure on time delivery to customers.

ÄEnsuring all established systems and procedures are followed to maintain and deliver quality product.

ÄEnsuring availability of raw material and other inputs to avoid delay in manufacturing delivery of products.

ÄPlanning, budgeting and finalizing layout for setting up fabrication facility to cater the new orders.

ÄMonitoring and reporting the profitability of the business and implement measures to improve the same.

Significant Accomplishments:

ÄEstablished project layout & planning, machinery procurement, process validation and SOP’s for execution of fabrication orders.

ÄAdded 1Cr to total sale in 3 months by completion of backlog orders.

ÄDeveloped MIS reporting system to monitor the progress of work, status of sale against target.

India Files Manufacturing Company, Una Jan’18- Feb’19

As Assistant General Manager- Manufacturing

ÄResponsible for execution of production as per schedule to ensure on time delivery to customers by ensuring all established systems and procedures are followed to maintain quality of product.

ÄMonitor and maintain factory overheads within target range for efficient working of plant by ensuring effective utilization of manpower, utilities and raw material. Managing fund flow for the plant to enable timely payments of vendors and other obligations in coordination with corporate finance department.

ÄEnsuring optimum level of raw material and other inputs to avoid delay in manufacturing delivery of products.

ÄInitiation of new projects for improvement in productivity, quality, cost and delivery.

ÄEnsure safe working environment in the plant. Liasoning with local authorities for routine legal and statutory matters.

Significant Accomplishments:

ÄReduction in RM procurement cost from 28.6% to 27.5% w.r.t sales by developing new RM sources. Reduction in administrative cost from 2.7% to 2.4% w.r.t sales.

ÄSuccessfully initiated & completed projects for improvement in performance consistency and reduction in customer complaints; Shop floor re-layout to improve material flow and reduce transportation time.

ÄISO 9001:2015 certification for the plant within 4 months of initiation.

The Indian Card Clothing Co. Ltd. Feb’13 – Jan’18

As Production Manager

ÄManaging entire manufacturing including Rolling, Punching, Hardening, Carrier Assembly and Tool Room operations. Managing a strong team of around 120 Diploma Engineers associates.

ÄEnsuring conformity to Product Quality standards by putting and ensuring adherence to standard procedures and improvements in the processes.

ÄEnsuring steps for realization of production plans and optimum utilization of man, material, methods & machines. Performing monthly analysis for planned vs. actual.

ÄMaintaining safe working environment by providing training to personnel for improvement in quality and productivity.

ÄImplementation of lean manufacturing concepts like 5’s, Kaizen, Autonomous Maintenance, OEE. Process improvement by Time Study, Standard Work, Visual management, SMED, Automation and Layout change.

Significant Accomplishments:

ÄImproved Delivery Schedule Adherence from 38% to 90% and reduction in backlog from 38% to below 2%.

ÄImproved in material utilization index from 37% to 29% by ensuring waste control measures.

ÄCost savings by salvaging the smaller tools blanks from bigger tools mainly in Carbide material.

ÄStandardizing RM wire size to reduce the input cost, inventory and improving quality.

ÄSuccessful in New project cost reduction from 1.25 Cr to 40 Lacs by layout change and Kaizen activities to support cost saving of 6.5L.

ÄSuccessful implementation of Kaizen, Standard Work, Visual Shop Floor, My Machine/My Area, OEE.

ÄSuccessfully implemented continuous measurement system on manual punching machines to stop the machine in case of measurement goes out of set limit.

ÄSuccessfully introduced NDT testing of weld joints to ensure acceptable weld quality.

Inox Wind Ltd., Una Apr’11 -Feb’13

As Assistant Manager- Production Planning and Control

ÄManaging PPC functions at plant level and responsible for job scheduling, and ensuring adherence to customers' delivery schedules. Forecasting and performing monthly analysis for planned vs. actual.

ÄCapacity and budget planning to ensure meeting of forecasting given by marketing. Implement cost reduction projects without affecting product quality. Revalidation of BOM for adequacy in actual assembly.

ÄLiaising with other functions for realization of production plans; ensuring optimum utilization of man, material, methods & machines. Responsible for Inventory Control & Material Management. Ensuring timely availability of raw materials for uninterrupted production related activities.

Significant Accomplishments:

ÄPlayed a major role in the identification and removal of non-value adding items from BOM and recycling of packaging wood material for use in dispatch of accessories of finished goods.

ÄSuccessfully increased BOM adequacy level from 90% to 96%. Achieved 100% on time delivery of finished goods to customer.

ÄEfficiently reduced transit damage of raw material by planning and implementing improvement in packing standards through logistics.

ÄReduced production downtime due to material shortage from 30% to below 10%.

Sigma Freudenberg NOK, Mohali Apr’02 – Apr’11

As Assistant Manager - Production

ÄManaged production activities and ensured compliance to quality control systems; steered strict observance of specified procedures to intercept materials at early stage for rectifications.

ÄProvided raw material for rubber molding process. Implemented corrective / preventive action based on the feedback from rubber molding process.

ÄHeaded a Production Team of Engineers and Operators to achieve ambitious production targets.

ÄImproved the process based on failure modes (potential & occurred) to develop product quality and technology and improve customer satisfaction on part quality.

ÄPrepared TS 16949, EMS documentation.

Significant Accomplishments:

ÄSpearheaded process improvements based on various feedback information from customers/ audit systems (QMS/ EMS / OHSAS).

ÄPlayed a major role in implementing process control to arrest process wastages and improvement in product quality by using concepts of lean manufacturing like 5’s, Kaizen and Quality Circle.

ÄInstrumental in increasing the utilization of baking process by 16.67% through cycle time reduction.

ÄProficiently achieved 30% reduction in consumables consumption.

International Tractors Ltd., Hoshiarpur May’99 – Apr’02

As Junior Engineer (Shift In-charge) - Painting Section

ÄFormulated and scheduled paint jobs and handled shift activities.

ÄCoordinated entire activities related to paint shop including pre-treatment plant, sheet metal and chassis painting line and testing of paint quality before and after application.

ÄHeaded a team of painters & workmen to realize maximum productivity out of team effort.

ÄPrepared QMS / EMS documents for the department.

EDUCATION

ÄB.Tech. (Industrial Engineering with specialization in TQM) from Punjab Technical University in 2011.

ÄPost Diploma in Computer Applications from H.P. Board of Technical Education in 1998.

ÄDiploma in Mechanical Engineering from H.P. Board of Technical Education in 1995.

PERSONAL DETAILS

Permanent Address : S/o Sh. Amin Chand, Village Paplohal, P.O. Dandwin,

Sub Tehsil Dhatwal (at Bijhar), District Hamirpur,

PIN-176040, Himachal Pradesh

Present Address : House No. 2046, Ambika Vihar, Ward No.4,

Kharar, Distt. Mohali (Punjab)- 140301

Date of Birth : 25th June, 1976

Languages Known : Hindi, English and Punjabi

CORE STRENGTHS

Lean Manufacturing

Production Planning

Team Management

Performance monitoring

Inventory Management

Quality Management

Cost Saving Initiatives

Process Improvement

Budget Control

Purchase

Liasoning

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