Prabodh Shrikrishna Kale

Sr. Manager,

ZF Steering Gear ( India ) Ltd., Pune.

Email: adh8sm@r.postjobfree.com

Tel: 2542 35 69 (R)

Mobile No. : 982-***-****

Address For Correspondence :- P.S. Kale c/o S.G.Kale

14,' RAJAS', Vinit hsg. Society,

L.I.C. Colony, Kothrud, Pune- 411 038

1. Objective : - To work in the area of Product Development / Engineering Projects by utilizing my knowledge & experience.

2. Additional qualification :- Post Graduate Diploma In Project Management, Tripura University, in May 2015.

3. Areas of expertise :-

New product development & implementation of Lean manufacturing.

Engineering / Automotive projects co-ordination & Implementation.

Design & setup new assembly lines & Prototype component development.

Process / Operations Planning & ISO documentation.

Capacity & Layout planning.

4. Note worthy contributions : -

A ) Installed Engineering projects in ZF Steering Gear ( India ) Ltd.

Inspected semi automated line at South Korea.

Design & installed complete assembly line for Bajaj Auto steering gear –

oDesigned assembly process sequence.

oDesigned assembly stations according to operator’s activities, fixture size, requirement of material/tools on station & space required for material feeding/ outgoing trolleys.

oDesigned packing solutions/trolleys for finished product.

Installed new paint shop which satisfies –

oQuality requirement of Domestic as well as MNC customers.

oMarket demand.

Implementing VSM in paint shop which will give –

oBetter utilization of manpower.

oReduce burden/fatigue from operators.

oAchieve efficient & qualitative work from operators.

oMaximize productivity.

oBetter co-ordination in related departments like Store, PPC, Purchase, Maintenance, Assembly, Machine shop & Dispatch.

oSmooth/Uninterrupted production output.

Installing material handling solutions in Production & Assembly area for –

oReducing manual handling.

oReducing damages during manual handling.

oReduce floor space & manpower movement on floor.

oReduce manpower.

oSmooth & single piece flow.

Installed 1 D Bar code system which connects Assembly, PPC, Paint shop & Dispatch for –

oTraceability of product testing parameters & manufacturing date.

oRecord the product sr. no. data.

oIdentification of Bar code no. on product & on packing box.

oLink the dispatch details ( like model no., Sr. no., manufacturing date ) with the dispatch invoices.

B ) Developed assembly lines for automotive components of Dana products like

Front live & dead axle assembly for Earth movers & Tractor.

oDesigned assembly process sequence

oDesigned assembly stations according to operator’s activities, fixture size, requirement of material/tools on station & space required for material feeding/ outgoing trolleys.

oDesigned packing solutions/trolleys for finished products.

Implemented Lean Manufacturing on existing Axle assembly line –

oAchieved 45% rise in productivity.

oReduced space.

C ) Involved in the vehicle parts development of Force Motors products like

Three wheeler & Four wheeler Minidor rickshaw

4 X 4 Traveler front axle.

D ) Developed components of Engines,Transmission systems,Chassis Engineering

& special attachments for two wheeler models of Kinetic Engineering like

125 cc Blaze Scooter, 100 cc Kinetic Honda & Nova scooter

65 cc Zing scooterate & 50 cc Safari moped.

5. Soft skills related to CAD / PLM systems :-

A ) Acquired training in Pro-E, CATIA – V5, Solid edge for solid modeling,

AUTO CAD for layout modeling & Factory Design Suite for shop floor modeling.

B ) Exposure to relevant areas of Team Center such as BOM, Navigator etc.

6. Brief about industrial experience:-

A ) Name of Company : ZF Steering Gear ( India ) Ltd., Pune.

Company Profile : Leading manufacturer in Power, mechanical &

Rack & Pinion type steering gear, Vane pump.

Duration : From July 2011 to July 2020

Department : Manufacturing Engineering

Designation : Sr. Manager

Role :

Engineering support to production & service department.

Setup new assembly lines.

Implementation of Lean manufacturing.

Improvements in material handling.

Utility support to manufacturing plant.

Responsibilities :

Concept designing, quotation collection from suppliers, costing, negotiations, procurement & installations of machines, engineering facilities/attachments, Poka Yoke, software systems ( like Bar code ) & designing of material handling systems to increase productivity, reduce man power, reduce burden on operator, reduce space.

Capacity planning & balance the assembly lines by implementation of Lean Manufacturing.

Concept designing of assembly stations, Assembly lay outing, decide manpower, arrange new assembly setup.

Assembly & machine shop re-lay outing for better material movement.

Provide utility support to manufacturing plant like installation of air net facility, Air supply unit, new Engineering setup, etc.

Installing & implementation of VSM for new paint shop to meet requirements of customers like Volvo & Daimler.

Installation of Bar code system –

Installed 1 D Bar code system to avoid wrong dispatches & keep records of product details with invoices.

Installing 2 D Bar code system which can trace the data of casting/forging material, semi machining data at supplier end, in-house machining & H/T data, assembly & testing parameters, painting, packing & dispatch details, etc. Integrate all level data with SAP.

Prepare & monitor PFD, PFMEA & Control plan to reduce line rejection, rework & customer complaints.

From last one year working as a Paint Shop Head. Handling all production & process activities. Handling 81 workers & 4 supervisors in three shifts.

B ) Name of Company : Dana India Technical Centre, Pune.

Company Profile : Leading manufacturer in Axles, Drive shafts &

Sealing products.

Duration : From June 2007 to July 2011

Department : Manufacturing engineering & Prototype

manufacturing.

Designation : Team Leader

Role :

New product development.

Setup new assembly lines.

Implementation of Lean manufacturing.

Prepare & control on assembly & machining processes through ISO

Documentation.

.

Responsibilities :

Manufacture proto samples.

New product assembly planning, sequencing, layout modeling, designing assembly stations & man power requirement.

Designing & arranging assembly fixtures & material handling solutions.

Increase productivity. Reduce man power, space, burden & WIP through implementation of Lean Manufacturing for assembly lines.

Continuous improvement through VSM & capacity planning.

Prepare PFD, PFMEA, Control Plan, Critical Process Alerts to control all assembly & machining processes to reduce rejection & PPM.

Validate Machines, Fixtures, Toolings, Poka Yoke, Material handling solutions, Assembly stations & Processes.

Control on processes by updating & reviewing PFMEA, Control plan, Fixtures, Poka Yoke.

Engineering support.

Additional Responsibility :

Coordinating & Handling Testing activities for DANA products like Drive shafts for heavy & light vehicles in ARAI.

Setup in-house Test Lab for DANA products.

C ) Name of Company : Force Motors Ltd. Pune.

Company Profile : Leading automotive manufacturer of

3 Wheeler,UV ( Trax), LCV( Traveler).

Duration : From September 2005 to June 2007

Department : R & D (Proto Planning Cell )

Designation : Asst. Manager

Role

Planning & developing Prototype components in-house and at suppliers’ end.

Responsibilities

R & D Projects Coordination related to

Prototype manufacturing of components for Three Wheeler & Four Wheeler Vehicles.

Arranging proto samples from sub sections like Machine shop, Fabrication, Sheet metal work, Model shop, Tool Room & from Suppliers’ end.

Planning & arranging raw material, special tools & machining facility.

Preparation of patterns for Alluminium & Cast Iron castings.

D ) Name of Company : Kinetic Engineering Ltd., Pune

Company Profile : Automotive manufacturer of 100 cc scooters

& 50 cc mopeds.

Duration : From April 1995 to September 2005

Department : R & D Projects

Designation : Superintendent

Role

New product development, in house & at suppliers’ end.

Responsibilities

Actively involved in prototype manufacturing & pilot lot machining of Steel, Cast Iron, Plastic, Aluminum, Press & Fabricated components

Designing & Planning of Jigs/Fixtures and Gauges.

Preparation of Process sheets.

Pilot lot manufaturing of automotive components. ( Lot size : 50 nos.)

Co- ordination with Design, Production, Service, Purchase, R & D, Accounts, Vendors, QC & Tool Room department .

Arranging PDC dies /Moulds /Jigs /Fixtures & receiver gauges manufacturing in Tool Room.

Tooling tryouts at vendor's site & inhouse.

Fitment of new developed components on engine & chassis.

E ) Name of Company : Intech Export Pvt. Ltd., Pune.

Company Profile : Manufacturing powder coating equipments.

Duration : May 1993 to March 1995

Department : Design & Development

Designation : Design & Development Engineer

Role : New product development.

Responsibilities : Designing powder coating equipments.

F ) Name of Company : Bajaj Auto Ltd., Aurangabad.

Company Profile : Two & three wheeler automobile mfg. company.

Duration : August 1991 to August 1992

Designation : Graduate Trainee Engineer

Role : Supervising the activities in a m/c shop of 3

wheeler Rickshaw plant.

Responsibilities

Machining of Aluminium components for Rickshaw engine

Handling 20 operators for aluminiumn machining line of engine components.

7. Education Qualification :-

BE ( Production Engg.) from Jawaharlal Nehru Engineering College,

Marathwada. University, Aurangabad in 1991 with First Class ( 62.4%).

8. Personal information :-

Date of birth : 10th May 1969

Nationality : Indian

Languages known : Speak : English, Marathi, Hindi.

Read : English, Marathi, Hindi.

Marital status : Married

Hobbies : Playing cricket & musical instruments. Carving.

Prabodh Shrikrishna Kale

Contact this candidate