Mr. YOGESH MADHUKAR MALI

Mobile: 897-***-**** E-Mail:adls1b@r.postjobfree.com

Seeking assignments in Production Department (Engine Assembly – Diesel Engines) with a growth oriented organization to utilize my skills & experience as a resource for all kinds of challenging jobs through leadership, creativity & teamwork.

Skillset

B.E. in Mechanical Engineering from Arvind Gawali College of Engineering Satara. Professional with 4 years of experience in Machine Shop (Gear Grinding) & Engine Assembly Production (3L & 5L Engine).

Hands on experience in New Assembly line set up activities, Line balancing activities, Manpower training for assembly, manpower management, TPM methodology etc.

Well trained for Engine Assembly, Testing and troubleshooting of assembly and testing issues/defects for Diesel engine.

Strong orientation towards achievement of production target with maximum utilization of resources & cross functional activities based on daily work management.

In-depth understanding of various systems & part functions of four stroke engines, assembly process defects while engine assembly, Motion loss reduction activities, Quality assurance activities while assembly.

An effective communicator with strong relationship management skills and analytical, problem solving & organizational abilities. Possess a positive attitude.

Profile Summary

Production Engineering Engine Assembly - Activities:

Managing the production tasks including planning, control & trouble shooting for achieving periodic schedules, manpower deployment on stages for engine assembly line & Compliance of production requirement.

Dealing with cross functional teams such as PPC, QA (vendor), Machine shop & vehicle assembly to achieve daily production & quality and required communications with concerns.

Daily production meetings, QSR meetings & follow up.

Daily Assembly & testing line concern resolution.

Monitoring the daily process audits, torque audit, PDI audit & kaizen/poka-yoke audit.

System Updating based on various feedbacks.

Daily quality status review with various departments such as QA, ME, PPC & Machine shop. Communication to concerns, follow up for action plan & check effectiveness.

Capacity planning & budget requirement preparation on yearly basis.

Analysis & action plan for in-process defects, cell defects, PDI defects.

Proactive activities for minor stoppages & line setting loss reduction on daily basis.

Cost reduction through monitoring & cost saving proposals through process/design change.

Monitoring of daily TPM board/activities for daily Overall line efficiency (OLE), RFT, QC table defects, daily stage working matrix & individual communication & actions on identified issues.

Monitoring of monthly TPM board/activities for improvement activities w.r.t. SQPDCME (Safety, Quality, Productivity, Delivery, Cost, Morale and Environment) & actions on proactively identified initiatives/projects for the same.

Tata Motors Ltd Pune at Senior Associate Position

Since Sept’ 16 to Sep’20

Engine Assembly and Engine Testing (Responsible for 3L & 5L Engine) Projects Accomplished:

Preparation of Line balancing for 25/shift, 50/shift, 100/shift & 200/shift

Output /man Improvement - Motion Loss reduction by using ECRS technique

Output /man Improvement - Generation of offloading proposals

Output per hour Improvement - Establishment of line balancing of 50, 100 & 150 per shift

OLE Improvement - Arrangement for keeping special tools on all stages

Quality Improvement - Proactive identification of defect possibilities & countermeasures

Quality Improvement - Establishment of subassembly processes at vendor's end

Cost Saving - Material cost saving through stage wise scanning of parts & design change

Implementation of assembly JH in Engine Assembly

Best assembly Practices for bearing pressing, Loctite application, O ring fitment etc.

SHE (Safety, Health & Environment) pillar projects/ activities – Safety Patrols, SOTs, etc.

Ergonomics Improvement - Ergonomic assessment of all activities by using assessment tool

Waste reduction - hazardous & non-hazardous waste

KEY SKILLS: Engine Testing

Conducting various tests on Engines, this includes mechanical development and Durability testing.

Good analytical, Capability of routing Engine Assembly, testing, PDI & Knowledge of Engine Failure Analysis.

Root Cause analysis & corrective actions for issues coming out to testing or field failure.

Analysing customer complaints through root cause analysis and PFMEA.

Daily production & testing problem related root cause analysis and resolution develop and implement production process.

Responsible to improve test cell utilization and implementation.

Material procurement for test cell related up gradation.

Daily monitoring the test data to check any abnormalities observed during testing.

Working on Eddy current dynamometer.

Carry out Different types of cycle test for the durability of Engine Such as

a.Oil Consumption Test

b.Full Throttle Test

c.Rated Power Test

d.Leakage test

e.Performance Test

Significant Achievements

Generated various proposals of kaizens for motion loss reduction by using ECRS technique Generated & implemented various proposals of design change to prevent defect possibilities

Generated various proposals of kaizens & Poka-yoke based on defect possibility matrix

Implemented various kaizens on hidden losses

Generate Poka – yoke while drive shaft connect with Engine it avoid housing damage.

Generate various Poka- yoke in testing bed like Engine clamping, Engine without oil etc.

Scholastics

2016 - B.E in Mechanical Engineering from Arvind Gawali College of Engineering Satara with 63.00%. Academic Project – Hog Ring Making Machine.

2011 - Diploma in Mechanical Engineering from Sharchchandrika Suresh Patil Polytechnic College Chopda with 68 %. Academic Project – Reverse braking System.

2008 - H.S.C.from A. S. C. College Chopda with 60 %.

2006 - S.S.C. from Vivekanand Vidyalaya Chopda with 71 %.

Software Skills

SAP Knowledge: Production data entry, Engine offline entry, Kaizen updating, Rejection entry.

Basic knowledge of Auto-CAD.

Basic Knowledge of Pro-e, Catia, U-G

Basic Knowledge of Excel, Word, power point

Personal Dossier

Date of Birth: 30th May, 1991.

Current Address: Flat no 3 Akshay Society Chinchwad, Pin. – 411033.

Permanent Address: A/P 4821, Malharpura, Tal – Chopda, Dist. -Jalgaon, Pin. – 425107.

Linguistic Abilities: Marathi, English & Hindi.

Passport: No.

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