Senior Process/Manufacturing Engineer Automation & Molding Expert

AVILASH KUMAR SHARAN

****/**, ******* *******, *** Pi 1 & 2,

Greater Noida (UP)

(Mob). +91-800*******, Res. +91-800*******

E-mail id: ********.******@*****.***, ********.******@**********.*** Head – Process/Manufacturing Engineering Assembly/Molding CARRIER SUMMARY-

Results-driven engineering professional with over 19 years of extensive experience in Process/ Manufacturing Engineering, specializing in Automation & Digitalization (IoT), Assembly, Injection Molding, and Blow Molding. Proven career progression from junior staff to leadership roles, demonstrating the ability to take on increasing responsibilities independently and within cross-functional teams. Recognized for strong leadership qualities, self-motivation, and a proactive approach to learning and applying new techniques and innovations

Technical Expertise:

• Automation: Robotics, Conveyors, Poka-Yoke, Automated Assembly

• Manufacturing Processes: Injection Molding, Blow Molding, Assembly

• Digitalization (IoT): Machine monitoring, SPC, EOL Integration

• Tools & Methods: DOE, SIM, APQP, FMEA, Control Plan, VA/VE, VSM

• Equipment: IMM selection, MTC, HRTC, CFS, dehumidifiers, gas injectors

• OEM Exposure: MSIL, M&M, HCIL, Suzuki 2W, Cummins, Tata Technical/Academic Qualification

• Diploma in Mechanical Engineering, Govt. New Polytechnic, Patna, Bihar (2004)

• Higher Secondary– BIEC (2001)

• Secondary (10th) – BSEB (1999)

Professional Trainings: -

• Toyota Production System (TPS) — 6-day certified training in lean methodologies, kaizen, and continuous improvement practices.

• Scientific Injection Molding (USA) — 5-day professional training on scientific Molding, polymer behavior, and systematic process control.

• Certified in Business Etiquette & Effective Presentation Skills for enhanced leadership and communication.

Global Project & Technology Exposure

• Executed international assignments across Europe (Germany, Switzerland, Poland, France, Hungary) for technology transfer and process localization of advanced plastic decoration technologies including IMD (In-Mold Decoration), INS (In-Mold Surface Decoration).

• Led end-to-end technology transfer, including supplier alignment, process validation, trial runs, and production ramp-up.

• Extensive exposure to Asia-Pacific regions (South Korea, Taiwan, Indonesia, Singapore, Malaysia) for Injection Molding, Blow Molding, and Assembly Line Setup.

• Managed machine trials, process optimization, buy-off activities, and production stabilization for new program launches.

• Hands-on experience in tool trials, parameter development, process window establishment, and cross-functional coordination with global suppliers and OEMs. Career Highlights

• Led the successful installation of 100+ assembly lines for components like Air Vents, Center Consoles, Cup Holders, Door Latches, Engine Parts like -Oil Pan and Valve Covers.

• Led IoT-based digitalization initiative at Minda Corporation as part of MSIL “Maintenance 2.0” compliance, enabling real-time monitoring of Injection Molding machines. Implemented digital check sheets and EOL tester integration to generate live SPC data for process control and audit readiness.

• Incorporating processes like Vibration/Ultrasonic Welding, Heat Stacking, and Infrared Welding from concept to SOP.

• Gained hands-on Surface Decoration Experience in Germany for an MSIL Project, after being selected for international training at MATE.

• Completed specialized process training and acquired cross-functional expertise in Germany, Spain, and Korea, applying best practices to optimize production processes.

• Implemented best practices and safety protocols during assembly line setup, achieving a zero-accident record.

• Designed and executed a fully automated Operator-less Assembly Line for Door Sash with 6-axis robotic force measurement.

• Led India’s first Ultra Sonic Robotic Mouth Cutting system for automotive ducts.

• Reduced rejection rates of Bubble Cutting (Air Duct) by 40% through the successful adoption of techniques learned from Korea.

• Reduced manpower from 180 120 within 3 months using VSM & LCA, awarded Star Employee of the Year.

• Reduced Molding rejection from 10% 2% through process optimization, Optimized the cycle time- Flanges, Radiator Fans, and Tanks by introducing Low-Cost Automation for rework process

• Installed and Commissioned a Fully Automated Robotic Paint Shop at Motherson, enhancing paint quality and operational efficiency.

• Played a Key Role in the Infrastructure Development of the MATE Tapukara plant, Minda Gujarat Plant and working on new Plant for Minda ensuring seamless operations and production readiness.

• Engineered and overhauled with the help of supplier, a decade-idle injection molding machine at MINDA (FCS & SM), replacing all electrical and hydraulic components, resulting in restored high- efficiency operation and consistent product quality. Present Occupation:

MINDA Corporation Ltd (IPD Division)

Head-SBU (Greater Noida & Gujarat Plant)– Manufacturing Engineering (Assembly & Molding), Feb 2020 – Present

Company Profile: -

MINDA Corporation Ltd (IPD Division), the company is engaged in: Manufacturing for Major OEMs like- MSIL, Suzuki, M&M, Cummins etc. Major Products like – Interior Kinematic Parts (AC Louvers, Arm Rest Centre console etc). Engine Plastic parts like Oil Pan, Intake manifold, valve cover etc. Job Profile: -

• Collaborate with customers and project teams to define and implement new product processes, ensuring smooth post-Molding operations.

• Finalize concepts and designs for jigs, fixtures, and SPMs, overseeing development, installation, validation, and handover to production.

• Select suitable inj. Molding machines and auxiliary equipment (MTC, HRTC, CFS, dehumidifiers, air ejectors, gas injectors, auto-purge units) based on product and process requirements.

• Support injection Mold design and material selection to ensure high performance, durability, and efficient Molding cycles.

• Coordinates with suppliers for jigs, fixtures, and SPMs, ensuring 100% on-time delivery and achieving 20% cost reduction.

• Lead cross-functional teams through Mold manufacturing, ensuring quality compliance and reduced rejection rates.

• Support greenfield plant development, including IMM procurement, Mold setup, and process establishment, achieving production readiness within 6 months.

• Apply DOE and SIM methodologies to optimize Molding processes, reducing cycle time by 25% and improving quality by 30%.

• Prepare APQP, FMEA to ensure smooth product launches and full quality compliance.

• Lead NPD activities (PTR, PPAP, MPT), achieving first-time-right results and reducing time-to-market by 20%.

• Drive productivity and cost improvements through VA/VE and low-cost automation initiatives.

• Provide customer support through rejection analysis, root cause identification, and implementation of CAPA.

• Maintain zero-defect through robust quality controls and proactive defect-prevention systems. PAST EXPERIENCE:

Feb-2012 to Feb-2020 Mar-2010 to Feb-2012 Sep-2006 to Mar-2010 Motherson Automotive

Bhiwadi: -

Lead – Manufacturing Engineering

(Assembly & Molding)

Feb”2012 to Feb-20

Radiant Complast

Bhiwadi,

Production Engineer March-

2010 to Feb. 2012

Sanden Vikas India Ltd,

Faridabad

Shift in charge (Molding)

Sep 2006 to Mar. 2010

Personal Introduction: -

Name : AVILASH KUMAR SHARAN, (DOB-12-06-1984)

Marital Status : Married

Sex : Male

Nationality : Indian

Hobbies : Listening to music, Watching quiz & knowledge-based programs I hereby declare that all the above information provided by me in this application is factual and correct to the best of my knowledge.

.Date- 15-02-2026 Avilash Kumar Sharan

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