Manager Engineer

SANJAY RAINA

+91-860******* ************@*****.***/*****************@*****.*** Pune

MANAGER – INDUSTRIAL ENGINEERING/PRODUCTION/ INBOUND LOGISTICS

Lean Manufacturing Cost Optimization Continuous Improvement Inbound Logistics

A performance focussed and results-oriented Industrial Engineering professional with 20+ years of experience in process improvement, cycle time/cost reduction, productivity increase across automobile, printing &air conditioning sector. Skilled at implementing continuous improvement initiatives and identifying inefficiencies and cost optimization opportunities. Proficient in conducting internal safety audits and risk assessment and implementing various measures to achieve high safety in the organization. Experienced in inbound logistics, managing suppliers and ensuring that the right material is delivered at the right location at the right time. Possess knowledge of ISO/TS-16949, 5s, Kaizen,PokaYoke & TPM, AutoCAD, and Basic MOST Applicator. Internal Auditor for OHSAS & ISO 14000. Team leader driving team efficiencies delivering results in a dynamic work environment.

KEY CAREER HIGHLIGHTS

Cost Savings/Optimization: Delivered cost savings of 25 lakhs/month through appropriate manpower planning, optimization in the body shop by implementing MOST/ STDS in Body shop and Man-machine Chart.

Process Optimization: Enhanced production output by 10%. Increased the output of M-300 line from 153 vehicles to 169 vehicles per shift.

TPM: Implemented TPM in Automax Limited. Implemented small kaizens 250 leads to increase OEE from 65 to 81.

Continuous Improvement: Mentored teams to perform lean manufacturing. Introduced and implemented the concepts of PokaYoke/5s/Kaizen/IE Concepts/7QC Tools.

Standardization: Recognized for achieving the 100% score in standardization principle during BIQ (Built-in quality) level3 certification. Demonstrates expertise in writing the process sheets and SOP and preparing PMFMEA, SFMEA, and Control Plan for the manufacturing process. Implemented work measurement tool MOST in Kirloskar Brothers Limited and Blue Star.

Health & Safety: Minimized the number of incidents. Ensured that all the stakeholders comply with the Health, Safety and Environment guidelines.

Operations Efficiency: Improved delivery efficiency by 20% by effective planning and implementing vehicle/ delivery routes. Reduced unloading time from 4 hours to 2 hours by introducing the dock wise unloading plan.

CORE COMPETENCIES

Production Operations HVAC Projects Industrial Engineering Time study using MOST Layout Designing / Line Balancing PokaYoke/5s/Kaizen/IE Concepts/7QC Tools Capacity Planning Manpower Estimation / Machine Utilization GMS Audit Process Improvement / Cost Reduction Documentation / MIS Supplier negotiations Supply Chain Management Vendor Management Supply Planning Man Management Shift Management Standard Operating Procedures (SOP) PFMEA/ SFMEA/ LEAN Manufacturing Team & Stakeholder Management

Knowledge of ISO/TS-16949 5s, Kaizen, Poka Yoke & TPM AutoCAD Basic MOST Applicator Internal Auditor for OHSAS & ISO 14000

PROFESSIONAL EXPERIENCE

GENERAL MOTORS INDIA PVT. LTD, Pune Feb 2013 – Jan 2021

Sr Manager Inbound logistics, Jul 2018 – Present Manager Industrial Engineering/ Production, Feb 2013 – Jun 2018

AS SR MANAGER – INBOUND LOGISTICS

Team Size: 5

Managed 3rd party logistics supplier and ensured that the right material is delivered to the right location on time, to the quality required and is cost-effective.

Achieved savings of 15 lakhs/month by changing the CBM rate to monthly vehicle rate.

Improved delivery efficiency by 20% by effective planning and implementing vehicle/ delivery routes.

Trained 100+ drivers and staff of logistic service provider as part of their training and induction program.

Reduced unloading time from 4 hours to 2 hours by introducing the dock wise unloading plan.

Reduced TAT for vehicles by 30 minutes by arranging extra space for returnable trolleys and bins on the shop floor.

Minimized the number of incidents and damage to the parts by 80% by introducing the double rod system at the end of the vehicle to avoid the falling of trolleys.

Avoided pilferage of trolleys in the vehicle by thoughtfully introducing and implementing the seal policy in the company.

Ensured that logistic service provider operates in accordance with health, safety and environmental policies and procedures.

Recommended optimal transport modes, routes or frequencies. Set KPI for the logistics service provider.

Involved in writing the process sheets and SOP for the manufacturing process and logistics.

MANAGER – INDUSTRIAL ENGINEERING/ PRODUCTION

Team Size: 3

Led the GMS, IE Activities in Press Shop and Body shop and formulated the daily production plan for press shop (CKD, PDC and Body line). Defined and documented standardize work for each line. Created a photo-based process sheets/ WI for each station. Resolved Line balancing issues on line, calculated manpower for new/existing model.

Increased production and minimized non-value-added time by introducing standard time data sheet (STDS). Developed accurate, operations-wide measurement standards and assisted in accurate sanction of the manpower.

Improved plant productivity by developing and implementing continuous processes that improved the method of operation.

Implemented global manufacturing system (GMS) and standardization on the shop floor as per the global guidelines.

Enhanced production output by 10%. Increased the output of M-300 line from 153 vehicles to 169 vehicles per shift by rebalancing the line Layout changes and removing the NVA online.

Reduced cost by 25lakhs through appropriate manpower planning, optimization in body shop. Increased utilization of manpower by implementing man-machine charts, layout changes, and implementation of STDS.

Facilitated export of vehicles to Mexico. Prepared all documents like SOS/ JES for whole vehicle plant and trained all line leaders. Received the long-pending BIQ level 3 certificate within 3 months.

Recognized for achieving the 100% score in standardization principle during BIQ level3 certification.

Mentored the IE Team to perform Lean Manufacturing timely studies by STDS (Standard Time Data Sheet) MOST, Stopwatch. Guided the Press Shop and Body shop team leaders for preparing the standardized document.

Part of the team for establishing the line up to the desired output is achieved.

Created monthly MIS for Press Shop/ Body shop director and Plant head. Capacity planning for press shop/ Body shop

Defined efficient assignment of Industrial and liaising engineering resources to support production.

Conducted internal safety audits and Risk assessment and implementing various measures to achieve high safety.

Carried out a Risk assessment (SFEMA) for every activity of SOS (sheet / Process sheet)

Dy. Manager - Industrial Engineering BLUE STAR INDIA LTD, Mumbai Oct 2010 – Feb 2013

Conceptualized and implemented IE Concepts in HVAC projects. Introduced the concepts of IE like MOST (Lean way), stopwatch (manufacturing units & HVAC projects) and demonstrated excellence in conducting Time studies.

Facilitated the receipt of an award from L& T for implementation of Best practices on Project site

Saved 8.4 lakhs/annum by reducing 10 manpower on Deep Freezer Line.

Led improvement in productivity of Danfoss Line from 15 to 20 machines/per shift by implementing MOST time measurement technique on line.

Prepared DFA/DFM, PFMEA, Process sheets, WI, Control plan, material handling for the product, and MIS for management.

Increased productivity (Duct installation) per person from 3 meters to 11 meters by implementing kaizens, 5's, proper planning, and good communication and Time Study.

Implemented 5's, KAIZEN and TPM implementation.

PREVIOUS EXPERIENCE

Manager - Industrial Engineering, Kirloskar Brothers Ltd Oct 2009 – Sep 2010

Sr. Industrial Engineer, Thomson Press (I) Ltd, Mumbai Aug 2006 – Sep 2009

Industrial Engineer / TPM Coordinator, Automax Ltd., Gurgaon Mar 2003 – Aug 2006

Production Engineer, Associate Engineers (P) Ltd, Faridabad Jan 2000 – Mar 2003

EDUCATION

B.E. (Prod.), Dr Baba Saheb Ambedkar Marathwada University, Aurangabad, Maharashtra, 1999

Certification courses

1.Certified MOST Applicator

2.Certified Lean six Sigma Green Belt- from KPMG

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