Manufacturing Engineering and Continuous Improvement Projects

BISWADEV SENGUPTA

Flat No. ***, *th Floor, Building No.28, Vijay Annex-III, Vijay Nagari,

Near Club Annex, Waghbil Naka, Off. Ghodbunder Road, Thane -400615. M: +919*********, +919*********

Email: ********.********@*****.*** ; *****************@**********.*** Skype : biswadev.sengupta

Seeking senior assignments in Operations/Manufacturing Engineering/ Process Engineering / New Product Development/Project Management / Production & Facilities Planning / Design & Development in a growth oriented organisation of repute. PROFESSIONAL PROFILE

A result oriented professional with 25+ years of experience in managing the entire Manufacturing & Process Engineering, Facility Planning, Project Management, Tool Engineering, QMS Implementation, New Product Development, Vendor development, & Tool Room Operations. Proficient in facilitating Plant Operations including manpower, inventory with an aim to reduce cost of operations, improve quality consistency and delivery schedules. A keen strategist with skills in conceptualising and effecting process initiatives to enhance plant efficiency & productivity. Skilled in improving and streamlining Operations which results in the increase of Operational efficiencies and Productivity, reduction of costs and increase Profitability.

Proficient in developing and improving processes & Factory modernization to stabilise products as per set parameters. Distinction of being associated with important developments which significantly benefited business across organisations.

Experienced in handling independent Greenfield project for setting up manufacturing unit. Pivotal in end-to-end planning & execution of engineering projects including Capital Budgeting, review, research formats, designs, commercial viability, ROCE/IRR calculations, design etc. Possess strong skills in Project planning & management and overseeing of end to end implementation & handling and execution of projects.

Resourceful at strategising techniques for optimum utilisation of manpower / machinery & reduction of Working Capital and OPEX.

Proficient in coordinating procurement involving vendor estimation, tendering, contract negotiations & finalization of Capital goods procurement.

Expertise in Lean manufacturing practices (Kaizen, TPM, Cellular manufacturing) Key competency in New Product Development - Technical feasibility and Costing for automotive engine & transmission components and complete process planning and engineering for complete automotive transmission manufacturing and product development as per APQP process. Distinction for being lead Internal Auditor for ISO/TS 16949:2002 Quality management systems. AREAS OF EXPERTISE

New Product Development

Technical feasibility, Manufacturing process planning and product costing for automotive transmission& engine components as per APQP process. Developing Process Sheets, Control Plans as per desired process to achieve drawing specifications. Key competency in the development of Gears (Spur & Helical) and other forged and machined components used in Automotive engines and transmission including submission of PPAP lot and sample development

Process Engineering & Improvement

Designing & implementing systems, processes and procedures to facilitate smooth functioning of overall production operations and enhance operational efficiency.

Driving Continuous improvement projects for all manufacturing units

Acting as a core member for enhancing the productivity and improving utilisation of machine tools.

Analysing various processes / applications and recommending process modifications and equipment calibrations to enhance operational efficiency and quality

Ensuring compliance of various quality measures.

Implementing TS 16949, ISO-14001 & OHSAS 18001 standards and maintaining the relevant documents.

Practicing quality standards with key emphasis on quality reliability. Green Field Project Execution

Complete Project Evaluation, Planning, Execution & monitoring from concept to commissioning.

Land acquisition and statutory obligations with State electricity board, Pollution control board, Factory inspector, Labour department, Excise department, etc.

Plant Layout and Material flow planning with optimum manpower and resources

Planning & procurement of Plant & Machinery and utilities

Installation & commissioning followed by trials and pilot runs & production in manufacturing lines Project Management & Business Strategy

Complete Project management and process planning and development of plant and machinery, development of general and special purpose machines for manufacturing units.

Financial analysis for Project management (Cash Flow, ROCE, IRR, EBIDTA, PAT computations)

Formulation of Annual Business plan including Annual Budget, Strategies and Profitability projections

Formulation of Strategic Business plan for margin improvement strategies

Formulation of Business Case for introduction of new business Plant Engineering

Improving and streamlining Operations to increase Operational efficiency

Optimising production shifts by utilization of resources

Introduction of TOC (Theory of Constraints) for reduction of inventory and cost of operations

Projects and initiatives with breakthrough changes in manufacturing processes to get positive impact on conversion costs

Establishing robust systems, processes & procedures in Operations

Institutionalize Process oriented and performance driven culture by developing competent team Capacity Planning

Developing new process concepts for production optimisation, yield improvement and develop guidelines for the sequencing of manufacturing activities on the shop floor (SOP).

Ensuring Capacity utilisation across manufacturing units

Setting up production targets and achieve the same within time and cost parameters.

Optimising man & machine utilisation to achieve pre-set production targets.

Overseeing production related tasks including planning, control and Trouble shooting Knowledge Purview

Machining processes and Gear manufacturing technology / processes (Hobbing, Shaping, Shaving, Tooth chamfering, Rounding, Broaching, Grinding, Honing, Heat Treatment and super finishing operations).

Design & functioning of the Gear boxes used in MCV’s & HCV’s.

Manufacturing processes for Steel rolling, Engineering files and Drills.

Workholding and fixturing systems for gear manufacturing processes.

CAD-CAM facilities. Proficient in usage of AutoCAD/PRO-E/ZW3D software for Jigs & Fixture design.

Quality system standards ISO 9000, QS 9000, ISO/TS 16949:2002.

Statistical concepts & quality tools PFMEA, SPC, MSA, QFD, DOE.

TPM, Six Sigma, Lean Manufacturing (Kaizen, 5S, Cell Production, JIT), SWOT Analysis, TOC.

Practising knowledge of Kaizen, TPM & TOC initiatives.

World Class Manufacturing tools – Cpk & Gauge R&R improvement & Poka Yoke.

Practising knowledge of SAP 4.6 – MM modules.

CNC Part programming on different Horizontal & Vertical machining centres for machining Auto components

(Fanuc, Sinumerik, Hinumerik controllers).

Project Management concepts and techniques for effective implementation of projects CAREER PROFILE

Since Feb’20 till date - Mumbai

Independent Engineering & Management Consultant

Working as an Independent Engineering & Management Consultant serving MSME’s across India. Providing consulting services pertaining to Business Strategy, Business Development, NPD, QMS implementation, Lean manufacturing, TPM, Operational excellence, TOC, Project management & general engineering and best management practices. Conducting trainings, workshops for clients for client team leadership development. Supporting clients to re-engineer and design the business processes and functions to improve the bottom-line. Also, support clients to identify key potential areas of improvement and help them to adopt new generation technology to implement radical changes for manufacturing and operational excellence.

Since July’16 to Jan’20 with Varroc Engineering Ltd. Aurangabad Associate Vice President – Engineering

Varroc Group : Leading player in Auto components with 4 business verticals (Polymer, Metallics, Lighting, electricals) and multiple manufacturing plants across the globe with an annual turnover of Rs 12000 Crores. Forging Business comprises of about Rs 700 Crores and caters to all major 2 wheeler OEM’s like Bajaj Auto, Yamaha, Honda, Hero Motocorp, Royal Enfield, Harley Davidson, Ducati, Kawasaki Motors, Suzuki to name a few.

Head of Engineering and R&D for Forging Business comprising of 3 plants in Aurangabad and 1 plant in Pantnagar, manufacturing complete transmission components for 2 wheeler OEM’s and other forged and machined components for automotive engine and transmission applications. Handling complete New product Development for all customers for domestic and export platforms. Driving plant modernization and re-layout projects in the plant as per lean manufacturing principles. Evaluating all capital investments pertaining to new projects and capacity expansions for the business. Driving all capacity expansion projects for premium customers like Ducati, Harley Davidson, Honda & Royal Enfield. Currently developing more than 80 components for different customers. Also developing customer specific designs for transmission components. Key member for devising future product strategy for the company. Responsible for all expansion projects for the Forging business. Since Apr’14 to June’16 with Hi Tech Gears Ltd. Gurgaon (Plant at Bhiwadi) Sr. General Manager – Engineering & Development

The Hi-Tech Group : Hi tech Gears Ltd is a leading player in the field of automotive transmission component manufacturing with 4 plants near Gurgaon with an annual turnover of Rs 800 Crores and caters to all major automotive OEMs like Daimler AG, JCB, Cummins, Magna Rico, ZF, Hero Motocorp & many others.

Head of Engineering & Development responsible for handling complete Business development, Engineering, Lean management, Tool Room & Tool Management for Transmission & Engine components. Handling the planning, scheduling and management of modernization & capacity expansion projects, ensuring completion of assignments within time and budgetary parameters. Evaluating major capital expenditure proposals to secure the best interest of the plant and increase productivity. Driving Capacity expansion projects for Daimler transmission gears and Timing gears. Developed 5 types of transmission components for Mitsubishi Fuso-Japan with process capability requirements on near to 50 parameters. Set up new manufacturing line at Hi Tech for manufacturing of Fuso Gears. Developed prototype components for JCB-UK for the Small Engine Family. Currently developing the ground engine gears for Daimler AG- Germany for the HDEP platform of engines. From Jan’14 to Mar’14 with Advance Cooling Systems Pvt. Ltd, Navi Mumbai General Manager – Operations

Advance Cooling Systems : Leading manufacturer of Panel airconditioners, Water & Oil Chiller units with 2 manufacturing plants in Navi Mumbai and caters to all major capital goods manufacturing OEMs in India and abroad with an annual turnover of Rs 100 Crores As Head of Manufacturing function handled complete operations for 2 manufacturing units including production, quality, maintenance, procurement, materials and related functions. Formulated strategic plans to enhance operations. Spearheaded Value Analysis/ Value Engineering & other continuous improvements in processes.

Conceptualized and implemented strict measures in operating procedures to optimize resource/capacity utilization.Developing production plans & schedules, arranging resources to ensure achievement of targets as per budgeted parameters.

From Apr’06 to Dec’13 with Raymond Ltd., Mumbai

Deputy General Manager – Modernization & Projects

Raymond Group : Incorporated in 1925, Raymond Group is one of India's largest branded fabric and fashion retailers. It is one of the leading, integrated producers of suiting fabric in the world, with a capacity of producing 31 million meters of wool & wool-blended fabrics. The Engineering Business of the Group comprises of Auto Components and Tools & Hardware verticals having 10 manufacturing plants and caters to the major OEM’s in India and abroad with a turnover of Rs 600 Crores. As Head of Engineering function, instrumental in successfully implementing Engineering Change management across all plants of Engineering Business with a positive impact on profitability of the company. Executed projects on modernisation of all engineering file manufacturing units to improve operating efficiencies thereby improving profitability ratios for engineering business. Set up new Transfer line with Single Piece Flow with a capacity of 1 Million Starter Ring gears / Annum for small ring gears catering to the car segment at Ring Plus Aqua Ltd, Nasik a subsidiary of Raymond Engineering Business.

Set up new Greenfield manufacturing facility (Concept to Commissioning) for engineering files, at Vapi in Gujarat with Lean manufacturing practices. Complete Project management and process planning including site selection, coordination with government bodies, plant layout design, and development of plant & machinery and utilities, development of special purpose machines for the new unit. Used “Early Management” concepts to design the plant

Jul’95-Mar’06: Tata Motors Ltd., Jamshedpur

Deputy Manager- Production Engineering & NPI

Tata Motors Limited (formerly TELCO) is an Indian multinational automotive manufacturing company headquartered in Mumbai, Maharashtra, India and a subsidiary of the Tata Group. Its products include passenger cars, trucks, vans, coaches, buses and military vehicles. It is the world's eighteenth-largest motor vehicle manufacturing company, fourth-largest truck manufacturer and second-largest bus manufacturer by volume. As Head of New product Introduction (NPI) for Transmissions & Power-train division, was instrumental in developing prototype and productionising new Gear box models for HCV’s and World Truck project. Complete process planning, design & development of tooling for various operations and complete coordination for prototype manufacturing of Gear box components through APQP approach. Prototype and Zero based process validation before handing over to Operations. Supported Operations in fixing process issues during serial production.

Program Manager for Development of new products of GBS-80, GBS-600, TC-400, GBS- 1400 & GBS- 750 gear boxes for heavy tonnage Tata commercial vehicles involving complete process planning, design and development of tooling for various operations and complete coordination for prototype manufacturing of Automotive Powertrain components. Team leader for developing first 9 speed planetary Gear box for Tata vehicles.

ACADEMIA

1995 B.E. (Production) from Birla Institute of Technology, Mesra, Ranchi; 1st Division with distinction IT SKILLS

Platforms : MS-DOS, Windows

Operating Systems : Windows XP, Windows 7, Windows 8, Windows 10 Software : MS-Office (Word, Excel, PowerPoint, Access), MS- Projects, AutoCAD, Pro-E, ZW3D ERP : SAP 4.6 MM Modules

TRAINING SCHEDULES

Industrial training on General Manufacturing Processes at Hindustan Motors Ltd., Kolkata.

Industrial training at Tata Motors, Jamshedpur and Tata Motors, Pune.

Training on Cutting Tool Technology & their Applications at Sandvik Asia Ltd., Pune.

Green Belt Training on APQP and Six Sigma conducted by Omnex Consultants.

Training on ISO/TS 16949:2002 (E) conducted by BVQI.

Training on Industrial Automation at IIT, Mumbai.

Technical & Management training courses conducted at Tata Motors & Raymond

Management Development Programme at IIM- Bangalore

FOREIGN INTERACTIONS

Wide Experience in handling and interacting with Foreign customers at Raymond Group (Customers like Valeo/Sata Sud/Winkelman/Cummins/Ege Sanayi/ Bellota/Befana), at Hi Tech Gears Ltd (Customers like Daimler AG/ Mitsubishi FUSO/ JCB/Cummins/Caterpillar/Magna Powertrain/CNH) and at Varroc Engineering

(Customers like Ducati/Harley Davidson/Meritor/Danfoss/ Kawasaki/Honda/Polaris) FOREIGN VISITS

Visit to PTJK Indonesia for implementation of manufacturing process improvements

Visit to Bellota – Mexico for acquisition of new technology for manufacturing of engineering files

Visit to Befana – Poland for acquisition of entire manufacturing facility

Visit to Lidsters – Sheffield UK for acquisitions of flute grinding machines for drill manufacturing

Visit to Ege Sanayi – Turkey for acquisition of entire manufacturing plant

Visit to Liebherr-Germany for component development and trials of Gear grinding machines

Visit to 5 plants of Daimler AG-Germany for technical discussions and new business finalization

Visit to Kawasaki Heavy Industries-Japan for technical discussions and new business finalization

Visit to Taiwan for development of new alternate sources of machine tools and work holding devices PRESENTATIONS/ TECHNICAL PAPERS/PATENTS

Special invitee for presentation on Lean manufacturing implementation by Kaizen Institute of India-Pune

Presentation on Best manufacturing practices at Engineering Business of Raymond at NITIE – Mumbai

Published technical paper in IJERT (International Journal of Engineering Research & Technology) on design of Accordion Spring for Automotive application

Developed unique design for One way Clutch for Two Wheeler Automobile and filed Patent OTHER DETAILS

Joining Period : Within 1 month Passport : Valid passport available

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