Project Engineer

PROJECT MANAGEMENT IN PROCESS DESIGN & PRODUCT DEVELOPMENT PROFESSIONAL WITH 14 PLUS YEARS OF EXPERIENCE FROM WELL-KNOWN AUTOMOTIVE SECTOR

CORE COMPETENCIES

Management;

Ability in achieving organizational goals through effective span of control of work force and act as a bridge between top management and operating level of management.

Technical:

Possess technical knowledge in Process, Automation, Gauging, metrology, inspection and, Engineering validation protocols/specifications, negotiations etc..

Problem Solving:

Qualified 6 Sigma GREEN BELT, ability to identify root cause and establish countermeasure using QC tools &, TPM methodology.

Systems:

Worked under ISO/TS 16949, ISO 14001 Environment system, and TPM,

Thorough knowledge in Delphi power train Documentation systems

Served as a global subject matter expert for machine qualification procedure

Served as a global subject matter expert for PPAP, PFD, PCP, PFMEA

Six Sigma – Green Belt

CARRIER PROFILE

PRESENT:

Caterpillar India Private limited, Chennai

Designation – Manufacturing specialist

Department - Manufacturing Engineering

Period: From April 2010 to till date.

ROLES & RESPONSIBILITIES:

New machines procurement, & commissioning and prove out

Continuous improvement in quality for provide Poka – Yoke in fixtures

Prepare standard work sheet & standard work element sheet

Participating in rapid improvement work shops

Prepare process flow diagrams and control plans

Prepare PFMEA along with Team and periodic Review

Participating in projects as a green belt holder.

Identify scope for internal failure reduction and by applying DMAIC and RCCA eliminate or reduce the scrap.

New machines Procured

Mazak Horizontal machining two pallet changeover machine

Mazak Horizontal machining Six pallet changeover machine

Gleason Gear machine

Achievements:

Certified Six Sigma Green Belt

Cycle time reduction by 7Hours

Banjo Cycle time reduction 10 Hours to 6 Hours (three operations to single operation)

A frame Cycle time reduction from 5.5 Hours to 2.5 Hours

Advance machining line in process gauging introduced in Differential carrier

Machines handled: HTC / HMC / VMC / VTC/ Gear hobbing and Shaping

(MAZAK, G&L, MVR, SNK, BSF, Toshiba, Okuma, Gleason, fellows Etc)

PREVIOUS EXPERIENCE:

Delphi TVS Diesel Systems Limited, Chennai

Designation – Team Leader / Sr. Engineer

Department - Production engineering department (widely known as Manufacturing Engineering)

Period: From November 2004 to March 2010

ROLES & RESPONSIBILITIES:

Project Management

Project approval from the management

o Concept, budget approval from top management

Equipments selection & Ordering

o RFQ, Selection of the machine supplier, Sanction approval from management & ordering,

o Equipments qualify, receipt & Installation, machinery deployment

o Machine proving, run @ rate, First time quality, plan vs. achievement, gaps identification, Validation submission and support the team until ramp up.

o Document preparation – Process flow diagram, control plan, FMEA, manufacturing drawings layouts, standard operating procedures, standard cell documentation etc.

Process handled

o CNC Turning, Milling, Electro chemical machining & debarring, Drilling, Tapping, threading, Gun drilling, deep hole drilling, High pressure debarring up to 2500 bar, EDM Drilling, Fluid grinding, Laser Marking, Cylindrical grinding, Internal and face grinding, Match grinding, Creep feed grinding, Flow test, Back leak, leak test, Nozzle final test etc.

Types of Machines handled

o Sliding head turning centers - Tsugami – Citizen , Tornos

o Turning centers – Tecno wasino, AMS , GD wheeler, Hardinge , shaublin

o Vertical machining center – Brother, Fanuc, AMS, Mekino Etc.

o Horizontal machining centers : AMS, Mekino, Turnmill centers : Nakumura,

o Electro chemical machining/ debarring – Elechem Technic, Dorner, Sermatec.

o Multi spindles – HMT ,Wick man, Cylindrical grinders – Micromatic , Bahmuller , Studer

o Center less grinders – Mikrosa, High pressure 2500 deburr – Aquarese

Special Measuring equipments

o CMM, Mahr roundness tester, Microna / Werth Optical measurements, Taly surf, Troppel Etc.

Major Projects Handled

VCO nozzle manufacturing establishment (Homologation)

o Total no of machines: 30 , Project cost: 26 crores ,Volumes / day = 2000 nos

o Worked as one of the leader in project for soft stage

BDN Nozzle capacity expansion

o Total no of machines: 12, Project cost: 11 crores, Volumes / day = 4000 to 5000 nos

o Worked as one of the leader in project and transferred

CR nozzle manufacturing establishment (GREEN FIELD PROJECT – NEW COMPANY)

o Total no of machines: 24, Project cost: 39 cr with Automation, Volumes / day = 2000 nos

o Worked as project leader

Exposure to Quality Systems:

o FMEA, Cp& Cpk, APQP, ISO 9000 & QS 9000,

o 5’S Housekeeping, TPM, and JIT, Flow manufacturing, single piece flow

o Kanban systems, POKA-YOKE, KAIZENS

o Visual Controls, standard work, Pull, Value stream mapping SMED

Vendor Development

o Detailed study of drawings, vendors selection, question quote, Manufacturing feasibility and quality level, supplier Audit and provide technical support during product development, Gauge and Mfg layout Layouts through CAD, Provide training to supplier about the Cleanliness level, KPC, QCI and other documents, ISIR and ample submission with PPAP. Tracking the project as per the APQP timing plan.

Overseas assignments

Training

Trained in Delphi Diesel Systems, U.K for VCO Nozzle manufacturing, & Delphi global system.

Trained in Delphi Diesel Systems, France & Common Rail Nozzle manufacturing

Trained in Delphi Diesel Systems, France for DDS procedures

Support

Japan visited for machine trails at citizen machinery, Wasino Machine tools for machine trails in 2005

Germany visited for evaluation machine tool supplier of extrude Hone, Dorner in 2006

Japan visited for evaluation machine tool supplier Citizen, Tsugami, Star, Wasino, Morigiseiko in 2006

Japan visited for machine trails at Tsugami and for evaluation machine tool supplier of Fanuc in 2007

Germany visited for machine trails at Dorner and for evaluation machine tool supplier Aquerese HP deburr machine supplier in France in 2007

SIGNIFICANT ACHIEVEMENTS

Localization of VCO Nozzle ,CR Nozzle production

Cost saving in the capex up to 30% in CR Nozzle

FTQ level better than lead site in Delphi diesel systems before SOP.

Nozzle soft stage line automation with minimum investment.

Poka - Yoke implementation,

QCT implementation to handle verity,

VCO nozzle time line met without delay

Lead the team (ME+ design + validation + QE) Route cause analysis for fatigue validation failure of CR Nozzle

(2)

Organization : Radiall Protectron Pvt Limited, Bangalore

French multination company manufactures of Co Axial connectors, Microwave filter, and Fiber optic cable connectors.

Duration : From Nov 1997 to October 2004

Designation : Senior Engineer (Quality )

SIGNIFICANT ACHIEVEMENTS

First time CNC Machines installations

BNC connector Developments

Microwave filters manufacturing development

Space Connector Development For ISRO

BNC connector Development

Induction brazing machine introduction in place of conventional Brazing

PERSONAL DATA

Full Name : STEPHAN BABU THOKA

Educational Qualification

Diploma in Mechanical Engineering

At Sri Venkateswara Polytechnic, Tirupati, in 1996 (65%)

B. Tech in Mechanical Engineering,

MGR University, Chennai, Tamil Nadu, in 2008 (80%)

Computer Technical Skill Set

Operating system : Windows95/98/NT/2000/XP

Application : MS office 98/2000/xp

Mechanical software : AUTO CAD,

PERSONAL DETAILS

Father’s Name : Munaswamy T

Date of Birth : 16th Mar 1975

Community : Christian

Nationality : Indian

Sex : Male

Martial status : Married

Languages Known Read & Write: English, Telugu and Hindi.

Converse: English, Telugu, Tamil, Kannada and Hindi.

Passport : F5133003

Address : Flat No G1, Plot No 6B, Reddiar Nagar

Balaji Nagar Extension, Korattor, Chennai 600076.

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