Handheld: +91-959*******/
Email: adumzi@r.postjobfree.com
adumzi@r.postjobfree.com
Accomplished professional offering a career of over 25 years in directing the entire gamut of Manufacturing Operations Inventory Planning & Control, Quality Management Systems(QMS), Greenfield and Brownfield Projects with key focus in ensuring optimal utilization of resources and (PQCDGSM) in
Engineering, Automotive & Auto-Ancillary sector
Profile Summary
Performance-driven leader with rich experience in operational excellence with an integrity to a “get it done” attitude without micromanagement and delivering spectacular results and winning teams
Holding strong relations with Key Decision Makers & Opinion Leaders in a competitive environment; successfully determined the true value and key performance drivers of a business to achieve equal top and bottom-line results
Incisive acumen in Manufacturing Operations and Plant Supervision, Production Planning & Control, Lean Manufacturing, TPM, TQM, Supply Chain Management, Inventory Planning & Control, Machine Installations, Manufacturing Layouts, Capacity Optimization and Greenfield Projects Industrialization
Showcased excellence in analysing process to provide critical inputs for improving business and formulating various strategies for process excellence
Expertise in managing the inventory function, inventory-holding cost reduction, wastage minimization and adherence of minimum inventory level, ensuring zero stock run-outs
Exhibited excellence in driving process transformations, capital expenditure management, waste reductions and P&L oversight
Pivotal in transforming the function into a value creation group by working in collaboration with stakeholders, cross-function partners, strategic supplier alliances to generate year-over-year productivity
Spearheaded international & domestic operations for the set-up standards with liability for strategic utilization & deployment of available resources to achieve organizational objectives(PQCDGSM)
Experienced in spearheading quality management for the plant including(QMS) TS-16949 such as APQP, PFD, FMEA, PPAP & Control Plan, ISO14000, ISO9001 -2015, ANPQP, Customer Specific QMS, Kanban, 5S, TPM & Poka Yoke, VSM,
WCM, Lean Manufacturing
History of excelling in introducing new organizational change and leveraging knowledge base with internal resources to facilitate business excellence
Core Competencies
Production & Maintenance Operations
Strategic Planning
Greenfield / Brownfield Project Management
Process/Manufacturing Excellence
Techno-commercial Operations
Compliance Management
Vendor Management
Quality Assurance
Team Building & Leadership
Notable Accomplishments
Played a key role in reducing manpower by increasing ratio of revenue per head by 12% in period of low demand and plan to continue with the ratio at high demand period
Gained recognition for achieving 82% OEE (output) within stipulated time as per production plan agreed with Planning Department along with production targets; ensured on-time delivery to customers as per desired quality and cost standards
Successfully achieved highest production and sales with improvement in output by 94% OTDs
Recognized for reducing scrap by 6% and rework by 8.7%
Spearheaded honing line transfer from customer (BAL) to MFPL facility within budget cost and project timeline
Key person in accountability generation in all departments and sections with more clear roles and responsibilities with JDs
Established time based improvement with short time and long term action plan
Spearheaded Greenfield projects Industrialization with stringent quality norms, European Technical specifications in planned timelines with far below budgeted Capex( 33%less).
Key player in Localisation of parts for import substitute for cost advantage of 23%.
Work Experience
Since Jan’21 with Mutha Founders Pvt. Ltd., Satara as General Manager (Manufacturing)
Key Result Areas:
Spearheading eight machining units spread nearby a Foundary Unit .
Engaged in Operations Management, Production, New Product Development, Maintenance, Quality, Supply Chain Management, HR
Formulating plans for overall technological upgradation along with QM systems for overall PPM reduction
Assessing and preparing frameworks for overall transformation from conventional work culture to World Class Organisational era
Providing support to the bottom line profitability through improved manufacturing throughputs
Collaborating with customers to improve overall SOB (Share of Business) for revenue generation
Engaged in monitoring and controlling PQCDESM (Productivity, Quality, Cost, Delivery, Environment, Safety and Morale)
Strategizing plans for improving manufacturing processes related to Products, Equipment, & Manpower
Assessing and:
oEnsuring installation & commissioning of equipment
oDriving Robotic Cells, Welding Fixtures, Line balancing, Cycle Time study. Manufacturing dash boards(Digitization)
Engaged in process mapping & Line Study for new models
Working on Toyota Production System and managing development of Jigs, Fixtures & Tooling for Machine Shop
Engaged in expansion of Process & Method Engineering footprint and Process Re- Engineering.
Ensuring to enhance & improve the Material Flow and Reduce Handling in Shop
Steering improvement projects related to Processes, Production efficiency, cycle time, capacity and process capabilities
Engaged in designing Digital Dashboards for analysis and taking appropriate decisions
Implementing predictive maintenance and statistical concept in production shop; key person in applying Lean Manufacturing concepts to achieve the preset goals using minimum inventory
Formulating efficiency improvement plans as a part of continuous improvement which led to profitability enhancement
Conceptualizing and implementing low cost automation to get cost benefits in terms of productivity, material handling or operator fatigue
Devising & implementing production strategies/plans in order to achieve the organizational production goals
Implementing cost saving techniques/measures and modifications for reducing expenditures and increasing operational profits
Developing project baselines; monitoring & controlling projects with respect to cost, resource deployment, time overruns and quality compliance for ensuring satisfactory execution of projects
Maintaining entire production related reports, inventory & stock requirements, material procurement plans and work delegation schedules (weekly & daily) for completion of production process
Ensuring product availability through consistent stock follow-ups and maintaining sound relations with vendors. Monitored product inventory, verified pricing and offers with margins in control and ensured SOP implementation and adherence further
Assuring that the assigned tasks are executed as per conformance with approved quality guidelines & strategies set-up for achieving highest quality & excellence standards
Evaluating and reviewing company's integrated operations, business practices, updating, streamlining opportunities, and eliminating non-value added activities
Directing and leading the manpower; imparting continuous on job training to the workforce regarding the new technologies and accomplishing greater operational effectiveness / efficiency
Setting-out quality standards for various operational areas and ensuring a high-quality customer experience.
Aug’16 – Feb’19 with Vega India Level and Pressure Measurement Pvt. Ltd., Pune (German MNC) as Head Factory Operations
Key Result Areas:
Directed technology transfer from parent plant Germany to India for the Green Field Project and leading capex planning and procurement of machines and equipment in line with German specifications.
Engaged in monitoring plant layout, Capacity Optimization and cellular assembly lines (one piece flow), low cost automations with the best man-machine combination possible and supervised the progress of complete production orders as per manufacturing plan
Successfully controlled OEE, MTBF, MTTR & OTD, COPQ,SHE (PQCDGSM) production planning through ERP system and inventories through Supply Chain Management
Pivotal in controlling projects with respect to cost, resource deployment, time over runs and quality compliance to ensure satisfactory execution of projects
Spearheaded operations for the development & implementation of standard operating procedures that enhanced service quality as per corporate standards & best practices
Steered the entire gamut of activities right from conceptualization to execution including finalization of technical specifications, procurement, vendor development (Capability and capacity assessments) scheduling, (SCM) progress monitoring, logistics to have on time receipts with stringent quality parameters and stringent inward quality procedures
Key person in developing strong vendor based locally and internationally for electro-mechanical sub-assemblies, machined components and equipment manufacturers
Played a key role in establishing control for complete supply chain management stream to avoid zero stock run-outs and minimum inventory carrying cost along with logistic and packaging developments
Collaborated with Business Leaders to understand strategic business objectives and formulated development strategies to meet current & future growth requirements
Previous Experience
Jul’14–Jul’16 with Welmade Locking Systems Pvt. Ltd., Bhosari, Pune as AGM–Manufacturing
Highlights:
Spearheaded strategic planning, outsourcing decision-making at the Production Department and organized manufacturing facility at world class level including QMS, Visual Management, Kanban, 5S, Value Stream Mapping, Ergonomic workplace
Key person in managing sourcing, procurement, installations & commissioning (European / Chinese Machines and Technology Transfer), hi technology machines (CNC & PLCS PMs), in-house SPM manufacturing, technology up-gradation, capacity improvements, plant layouts and utilities.
Ensured Manufacturing Excellence through Lean initiatives (VSM, Line balancing, Visual management, WIP and Inventories)
Engaged in monitoring OTDIF, PQCDGSM, MTTR, MTBF, OEE, COPQ and overall profitability for manufacturing business
Co-ordinated for HROD activities (Human Resource Organizational Development) and took process level initiatives to develop team performance
Aug’13–May’14 with Diehl India Pvt. Ltd., Hinjewadi, Pune as Head–Manufacturing and Projects (German MNC)
Highlights:
Successfully directed Green Field Industrialization Project within stipulated time for technology transfer from parent plant at Germany and Machine installations at India plants
Monitored overall Capex Planning, budgeting and control for manufacturing operations & ROI controls
Engaged in New Product Development planning and streamlining manufacturing operations for NPDs
Gained recognition for attaining total project cost reduction by 40% through pragmatic & viable local solutions to utilities, machines and equipment & infrastructure development; pivotal in implementing procedural part for QMS–TS-16949
Dec’08–Jul’13 with WIKA Instruments India Pvt. Ltd., Pune as Section Head Assembly (German MNC)
Highlights:
Key person in formulating strategies, budgets & production schedules for the production operations along with resource allocation and machine loading for optimum output
Successfully assessed and rendered recommendations on Overall Equipment Effectiveness (OEE)
Played a key role in implementing Cellular Manufacturing Concept (Lean Layouts) at assembly & machining lines, that resulted in decreasing in-process inventory by 15% and increasing floor space utilization by 22%
Gained recognition for steering productivity improvement by 18% & manpower reduction by nearly 20% through line balancing; reduced input material cost by 24% for 25 parts through localization of import substitutes
Nov’05–Nov’08 with Spicer India Ltd., Chakan, Pune (USMNC) as Assistant Manager (Technical Services Group)
Feb’04–Nov’05 with Concentric Pumps (I) Pvt. Ltd., Pune (British MNC) as Production & Process Engineer
Sep’00–Feb’04 with TBK India Pvt. Ltd., Pune (Japanese JV) as Sr. Engineer Production & Manufacturing Engg.
Trainings Attended
Training for Technology Transfer, Plant Layouts and Machine Installation at Parent Plants in Germany
Training on Renault – Nissan specific ANPQP and ASES
PFMEA
Anand Performance System (Similar to Toyota Production Systems)
ERP- Top Viz/ Baan/ Axapta / SAP
Employee Involvement Programme
QCOS
Advance Tooling For Machining Centers
GD &T
SPC
Presentation & Communication Skills
IT Skills
MS Office
AutoCAD
MS Projects
ERP- Baan, Axapta,Top-Viz,SAP.
Knowledge Purview
Experience in SS, CI, SGI machining for differential housings, cooling pump housing, Ferrous & non-ferrous metals machining of engine parts and brake parts
Top notch Lean manufacturing expert with excellence in managing assembly lines of different products
Managed 1 Green Field and 2 Brown Field Projects with successful production
Conversant with CNC Machines (CNC Turn / VMC /HM Machining Processes, CNC Tooling, Assembly Process, Pressing, Forming, Welding, Jigs & Fixtures)
Exposure to the concepts of Lean Manufacturing, Kanban, VSM, WCM, 5S, TPM & Poka Yoke
Managed NPD activities along with vendor development and management
Techno-commercial aptitude with negotiation skills and networking skills with good product costing and manufacturing costing knowledge
Understanding of QMS /TS -16949 Documents like APQP, PFD, FMEA, PPAP, CAPA,8D & Control Plan
Manufacturing Operational costing, Budgets and control to support bottom line-Profit And Loss
ROI monitoring and controls
Knowledge of ERP Systems like Top Viz, Axapta, Baan & Mfg-Pro
Greenfield Projects Industrialization
Academics
P.G.D.B.A. (Operations) from Symbiosis Institute of Management, Pune. Pursuing.
B.E. (Mechanical Engineering) from College of Engineering Kopargaon, Kopargaon, Pune University in 1996
Personal Details
Date of Birth: 30th August 1972
Languages Known: English, Hindi and Marathi
Address: 'ShramSafalya',283/51,NearPodarInternationalSchool,Tanajinagar,Chinchwad, Pune–411033
Nationality: Indian
Marital Status: Married
No. of Dependents: Three
Passport No.: Z4003433
Visa Status: 5 Times German Visa
Driving License: Yes (MH 142**********)
Pravin Nanasaheb Badadare .
General Manager (Manufacturing Operations)