Manager Plant
Resume:
MAULESH R PATEL
Aurora, IL
adcl7b@r.postjobfree.com
U.S. Permanent Resident ('Green Card Holder'), able to work anywhere in the USA
PROFESSIONAL SUMMARY
Extensive experience as ferrous foundry plant manager interested in pursuing a career in "the Foundry Manager " in your organisation, to aid the foundry engineering sector in manufacturing, and quality at the most competitive prices with minimum lead time by guiding, coaching and supervising to engineering team to achieve goals and objectives.
CORE COMPETENCIES / TECHNICAL SKILLS
Process control & continuous improvement Quality improvement Identification of defects and determining associated corrective and preventive actions Coaching, guiding, advising, insuring and supporting team members for cost reduction programs, Failure, and defect analysis Multiple projects management Good communication, presentation skills Good analytical ability Excellent in cost analysis working for all processes Critical thinking and problem solving Excellent convincing skills Leadership, decision-making, Self work attitude Computer skills microsoft office - excel, PowerPoint, word, outlook Ability to communicate effectively. Adaptive to changing environment Planning & people management skills Lean manufacturing
PROFESSIONAL EXPERIENCE
Magotteaux Inc., TN, USA. 06/2016 – 05/2019
Manufacturing system manager –
Coached and guiding a global team of more than 30 people across the US, Europe, and Asia.
We are aggressively supporting manufacturing cost reduction, root cause analysis, and customer requirements.
Help, advise, and support worldwide plants that face any technical operations concerns like quality, cost, lead time, and process; also, ensure, develop, and implementation of best practices.
Provide ongoing technical assistance to Plant in the form of the metallurgical, production process, gating, risers, pattern layout, and casting defect analysis.
It established a robust link between the OEM customers' needs and the Magotteaux offer to maximize the added value for both Magotteaux and its customers.
Provided a multi-faceted Magotteaux interface to the customer in close collaboration & liaising with all internal stakeholders, across region, sales, marketing, manufacturing, standardization & R&D.
Established a constructive relationship with the original equipment manufacturers OEM like B&W, Policies, Pfeiffer, Mitsubishi, Hitachi power systems in a mindset of co-development in close collaboration with regional general manager, commercial/marketing.
Work with a wide variety of people in a different situation, effective in resolving customer issues in a timely fashion.
Achievements / Key Accomplishments:
In Thailand, Plant achieved a 30% cost reduction.
Increase the induction furnace lining life by 50% in Thailand plant.
In India, Plant reduced rejection from 8 % to 5% by standardizing gating, risers, and controlling the overall process.
It was created and established direct riser pouring in high chrome and high chrome ceramic castings, which resulted in a yield improvement of 5% and fettling/ grinding work reduction by 20%.
By foundry process improvement – achieved zero customers complain/Rejection in duo-cast casting product.
B&W is the biggest customer for VRM foundry – achieved zero customers rejection at customer end.
Management requested to take charge of interim plant manager in Q4 2018 as interim plant manager in India, and we achieved Record-high production (525 MT/ M), dispatched with 5% rejection, and established the benchmark at all KPI.
India plant production increases by 50%, resulting in a reduction of productivity with a 5 % rejection.
Magotteaux Ind Pvt Ltd India, and Thailand. 09/2012 – 06/2016
Plant Manager
MIPL Manufacturing of 'wear resistant' castings (in ductile iron- duo cast, high chrome, alloy steel, Ni-hard, with various type of ceramic Castings) which are supplied to renowned to OEM and companies in cement, utility and mining sector, which are a high mix – low volume foundry.
Succeeded as a unit head in strategic & operational issues about Improvement in operational effectiveness of the foundry unit.
Day to day follow up and coordinating with development, planning, production (moulding, melting, core shop, heat treatment, fettling, machining) maintenance, QC, EHS, and lean departments for daily operations.
More than 50 % of the time spent on foundry production shop floor observing points related to 5S, lean, process, and always asking the question "why?" and "how to do better?".
Responsible to achieve Key KPI: environment health and safety- zero Accident, > 95 % on-time delivery, <5 % rejection, <150 productivity, reduced operations cost-5%, production & dispatch.
Develop and manage plant annual budget and CAPEX.
MIPL produced vertical rolling mill -VRM casting like various types of rollers, roller segments, rings, ring segments, hollow balls, etc. using Magotteaux standards & the weight range from 50lbs – 22,000 lbs.
Coached, trained, and guided a group of managers, engineers, and supervisor staff in various depts.
Developed and performed all actions from forecasting to production planning to all subsequent steps that are required to meet deliveries.
Developed competence and skills in people specific to functions & standard operating procedures.
Ensure customers' satisfaction by achieving >95% OTD & establishing effective communication.
Responsible for timely recruitment and training of employees.
KEY ACCOMPLISHMENTS
Turned around the plant performance – 2M USD per year loss in the year 2011 & 2012 to Profitable company within six months by controlling the rejection < 5 %, cost, and productivity.
Significant changes in pattern layout, match plates, mounting system, and introduce the method Card system and finally standardizing the process related to the pattern.
Negotiated contract with vendors in 2013 and achieving payroll administration costs down by 35 %.
By achieving all the targets, management approved Capex for a new project every year and increased the plant capacity by 50%. - from 4000 to 6000 MT/ Year within three years.
Management gave additional responsibility to the Thailand plant as plant manager in 2015. The plant was making more than 2M USD loss per year since 2012, and the plant was the first time in 1% Profit in 2016.
Created method card with all micro details, in addition to that created melting, moulding, and heat treatment process control sheet with every process control steps.
Achieved various certification like ISO 9001: 2008, ISO14001:2015, ISO50001:2011, OSHA
When I moved to the USA, because of excellent performance management gave the position at the group level as a manufacturing system manager.
Reduce machining time by 50 % in wear resistance castings.
Himgiri Casting Pvt Ltd.- HCPL – "Ductile Iron" and "Grey Iron" Foundry, India 07/2010 –08/2012
CEO
Greenfield project – setting up the development department, manufacturing, metallurgical & physical laboratory with full utilization within three-month time. Which are a low mix – high volume foundry.
Train and help managers and engineers to achieve various department targets.
Produced various type and size of the product like mechanical-joint fittings, valve, fire hydrant, and customer were Sigma and McWane India Pvt. Ltd. (MIPL) using customer QIP with American Water Works Association-AWWA ref std. Also producing automotive products using commonly agreed on QIP.
Drawings study, give an estimation, finalize the layout of pattern, develop a pattern, do the getting and riser in the pattern, develop method card with process control parameter, take proto casting trial- batch production and start mass production.
Shop wise planning of production for induction furnace melting, coke-less cupola (gas base), KOYO Make high presser green sand moulding, no-back and shell core making, fettling, and machine shop.
Maintenance of medium frequency induction and cupola furnaces.
Co-ordination of marketing and purchase functions for meeting the customer's requirements.
Magotteaux Ind Pvt Ltd India. 05/2009 – 06/2010
Plant Manager
Manufacturing of 'wear resistant' castings which are supplied to renowned to OEM and companies in cement, utility, and mining Sector.
Succeeded as a unit head in strategic & operational issues about Improvement in operational effectiveness of the foundry unit.
Day to day follow up and coordinating with development, planning, production, maintenance, QC, EHS, and lean departments for daily operations.
Responsible to achieve key KPI: Environment health and safety- zero Accident, > 95 % on-time delivery, <5 % rejection, <150 productivity, reduced operations cost-5%, production & dispatch.
Develop and manage plant annual budget and CAPEX.
Coached, trained, and guided a group of managers, engineers, and supervisor staff in various depts.
Developed and performed all actions from forecasting to production planning to all subsequent steps that are required to meet deliveries.
Developed competence and skills in people specific to functions & standard operating procedures.
Ensure customers' satisfaction by achieving >95% OTD & establishing effective communication.
PMT Machines Limited - Project, India June 2007 – April 2009
Foundry Project Manager
Managed and designed the foundry plans for ductile iron windmill castings, resources, and land acquisitions with collaboration with German consultant.
We acquired all government licenses and permissions to proceed with the plan.
Unfortunately, the project got postponed because of the recession in 2008 and 2009 in India/the world during that time.
Sensitive Industries Project - Ductile iron foundry, India Jan. 2006 – June 2007
Manager - Project & Foundry
Lead and manage ductile iron automobile parts foundry.
Planner & designer of this greensand foundry from land to production stage within six months.
Bring order, develop pattern (getting and riser), and deliver the casting Ontime.
Training, encourage, and motivate each operation, supervisor, and engineer in all departments.
Achieved targeted mould production, liquid metal output, power consumption, Rejection within six-month time.
Set process parameters and achieved 4% Rejection.
Hindustan Gas Industries Ltd. Malleable & Ductile iron castings, India
DGM -Production Aug. 2003 – Dec. 2005
Production Manager (started as GET) April 1992 – April 2000
Lead the production department, which produced various types of Insulator castings and automobile castings in ductile iron and malleable iron using green sand mould production and main and medium frequency Induction furnace and coke base cupola furnace.
I started the career as a graduate trainee engineer and subsequently promoted up to production manager.
Lowered power consumption by 7%. reduced the rejection of malleable and ductile iron castings by from 8 % to 5 %., achieved higher production year by year.
Responsible for production planning, production targets, power consumption, and Rejection control.
Increasing production year by year by time study and time management.
Archived record break production as individual handling shifts as well as during production manager.
Mahavir Castings Ltd. Ductile iron & Grey iron castings, India
Production Manager Feb. 2001 – Aug. 2003
Produced textile, earthmoving parts, and automobile parts in ductile iron.
Change the process of ductile iron metal manufacturing and produce the ductile iron with duplexing with coke base cupola furnace and induction furnace metal, resulting in production increase, rejection reduce, and power consumption also reduces.
EDUCATION
M S University, Vadodara, Gujarat, India.
Bachelor of Engineering in Metallurgy.
Directions Training Center, Inc. USA
Lean and Six Sigma Greenbelt.
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