AKHIL TAYAL

Ashiana Orchids, Flat No. E***, Plot No. GH-01, Gamma 2, Greater NOIDA - 201307, Uttar Pradesh

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Contact No.: +91-981*******, 012*-******* E-Mail: ts0gwz@r.postjobfree.com

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Manufacturing Operations ~ Process Development ~ New Product Development

Automobile / Plastic Industries

________________________________________SNAPSHOT

Career spans nearly 14 years of experience in Manufacturing Operations, New Product Development, Production, Quality, Process Improvement, Value Engineering and People Management.

The wealth of expertise comes from working across Plastic Moulding and Electronic industry.

Currently working with Moser Baer India Limited as Senior Manager – Engineering & Technology; dealing in Manufacturing of Optical Storage Products.

Proven abilities to enhance the production process operations; optimize resource & capacity utilization, escalate productivity & operational efficiencies; while curtailing costs & expenses across organizations.

Possessing sound knowledge of Plastic Technology, adept in updating latest Technologies and instrumental in proposing solutions to optimize Production in compliance with the Quality Procedures.

Adept in Design & Development of New Product, moulding Design Review, Cavity Utilizations & Process Engineering activities, ensuring smooth flow of material through optimized work place layout.

Skilled in Assembly Related Work, Plastic Injection Mounding Process, Product Design and development.

Well versed with SPC, MSA Quality Tools, 7QC Tools, SMED Concepts, FMEA, PPAP (QA activities) and QCC quality practices.

Distinction of developing and filing a patent for Thin-DVD ROM.

Developed Alternate Reflective layer Material for CDR, DVDR & Blu-Ray Disc & patented in US, Europe, India & Taiwan.

Deft at carrying out time study, method study, worker output study, machine/ man efficiency study, process improvement, etc. Possess exceptional work ethics, routinely use available time to solve problems; ability in multi-tasking and timely completion of all assignments.

Distinction of developing new product namely HD-DVDR (Moser Baer was the 1st company in world to deliver HD-DVDR commercially) & Blue-Ray Disc.

Areas of Expertise include:

~ Project Management ~ Plant Operations ~ Production Engineering ~ R&D / New Product Development ~ Feasibility Study ~ Plastic Moulding ~ Quality Assurance ~ Process Excellence ~ Vendor Development ~ Technology Transfer ~ People Management

________________________________________NOTABLE ATTAINMENTS

Designed and developed Worker Rating System to measure efficiency and control normal production.

Developed Indigenous Mould Parts for reducing cost & optimizing life cycle.

Played a pivotal role in reducing cycle time for productivity enhancement without compromising on quality.

Initiated many cost reduction activities by modification in manufacturing process, using Alternate Material, challenging the consumption norms, setting new targets, and setting new consumption norms.

Instrumental in Master Production schedule in coordination with Raw Material Planning, Machine Scheduling, Parameter Setting and Calibrating for meeting Productivity Capacity Requirements.

Managing a skilled team of Executive & Production Engineers for supervising the Daily Operations and recognized for excellent Communication, Interpersonal and Team Management Skills.

________________________________________CORE COMPETENCIES

Project Management:

Responsible for managing overall project related activities (from deciding the layout to meeting customer specifications & interaction and technology transfer across the Globe.

Leading project conceptualization, basic engineering, detailed engineering, estimation, planning & implementation of project plans within preset budgets and deadlines.

Planning for optimizing man & machine utilization, reducing wastes for enhancing productivity.

Manufacturing Engineering

Overseeing production related tasks including planning, control and troubleshooting of plastic components & material and Optical Storage products.

Handling capacity enhancement and cost reduction initiatives and ensuring escalation of plant productivity.

Introducing process controls and consumption norms to avoid process wastages.

Implementing project plans within deadlines and defining best practices for project support & execution.

Preparing engineering samples from Moulding process side and involved in Resource Allocation & Utilization and conducted requisite Training Programmes Supervising production activity and achieving minimum rejection through rejection analysis on daily basis.

Overseeing production operations entailing product development activities as per changing market needs, vendor management, as well as handling industrial relations.

Conducting regular inspection and tests to ensure the process capability of various machines and effectuating various energy conservation programs.

New Product Development

Studying the system and package based on the surrounding components for development of new products.

Coordinating the entire product development activities including requirement analysis, planning, finalizing specifications and prototype and off-tool parts development.

Suggesting new ideas; preparing project plans and technical specifications for smooth execution of projects within the time and cost parameters.

Dealing with suppliers for managing quality /quantity of incoming material and implementing strict quality measures to ensure quality of the materials/ equipments and reducing rejection level to minimum.

Troubleshooting all technical problems; ensuring that the work executed are in compliance with the pre-set quality specifications. Troubleshooting fixtures, tools & machines.

Process Engineering/ Quality Assurance

Identifying assignable and chronic causes by the use of latest analysis techniques for eliminating wastages while enhancing plant efficiency and productivity.

Working towards cycle time reduction, scrap reduction, set up and change over time reduction, process flow improvements as well as throughput time reduction.

Ensuring adherence to quality standards & maintaining all related records and documents.

Monitoring the quality of products during the entire production process.

________________________________________CAREER CONTOUR

Since MM’ 99: Moser Baer India Limited, Greater NOIDA

Senior Manager – Technical R&D, Engg Section, Greater Noida Plant, U.P. (June 2009 onwards)

Moulding Production, Phase 2, Noida Plant (May 1999 – June2009)

At Engineering Section:

Steering complete manufacturing and new product development functions.

Overseeing design and development of new product process for Advance Format’s like – HD-DVDR & Blu-Ray Disc and moulding process for preparing engineering samples for any new development.

Identifying cycle times and normal production rates to synchronize with industry standards.

Developing Blu-Ray Disc & set-up process as per mutually agreed Time Lines with technology developer partner.

Obtaining Customer Qualification from leading market supplier for DVDR in Japan, Europe, US market.

Overseeing development of Platinum DVDR & it's qualification from MAM-A, USA.

Developing moulding process and preparing engineering samples for qualification and review.

Attainments:

Pioneered the successful technology transfer of DVDR Technology & started production in MAM-E, France.

Pioneered the successful technology transfer of DVDR Technology & started production in MAM-A, USA.

Played a vital role for developing Thin-DVD ROM & filled for Patent and instrumental in new Product Development activities.

Played a vital role in developing Alternate Reflective layer Material for CDR, DVDR & Blu-Ray Disc & has filled patent in US, Europe, India & Taiwan.

Played a vital role in finding an innovative solution for enhanced Light Fastness in Azo Dye Based products.

Successfully proposed & implemented continuous improvement activities through changing Moulding Process for Cycle times and Raw Material Consumption.

Successfully developed alternative machines at low cost with improved productivity.

Recognized for effectively managing the Product Development from designing to successful launch & implementation into production.

Attained significant reduction in various Cost Reduction Projects through implementation of QC tools.

At Moulding Production Section

Spearheading entire operations for installation & commissioning and production activities for moulding machineries in the company.

Performing upkeep erection, commissioning, preventive maintenance & troubleshooting of plastic injection moulding machines including process adjustment on new installed machines.

Generating monthly MIS with regards to total production & yield.

Identifying corrective action and monitoring troubleshooting & in-process quality activities.

Training manpower and leading the team for Continual Improvements through QCC Programs.

Attainments:

Steered the entire project related activities (from deciding the layout to meeting customer specifications), involved in client interaction and took action in case of any non-conformance.

Significantly reduced the downtime of Mould/Moulding Machine and proposing continuous improvement activities through regular monitoring of cycle times and raw material consumption.

Instrumental in ISO-14001 system implementation in the organization.

Recognized as Key Member of `5S’ and Quality Circle Evaluation and Checking Committee.

Feb’ 97 – Apr’ 99: Jay Yuhshin Limited, Gurgaon as Assistant Engineer

Machines Handled: Windsor, Hwa Chin, Fu Chin Shun, Victor and Engel Machines with tonnage from 15 to 450 tons with Robot arm.

Clients handled: Maruti Udyog, Hero Honda, etc.

Role:

Administering complete production planning and quality control functions in the company.

Managing production, System Implementation (ISO-9001), troubleshooting, in-process quality and manpower management functions.

Documenting daily production reports and rejection data and generating monthly utilization reports with MIS and conducting Quality Circle Review Meetings.

Attainments:

Instrumental in maintaining high quality standards & executing various activities in compliance to the assigned guidelines (SPC, One point Standard and Quality Feature Standard).

Successfully optimized Moulding Process Parameters for new product development.

Aug’ 96 – Jan’ 97: Sharad Electronics, Faridabad as Trainee Engineer

Role:

Developing overall production & machine scheduling activities and coordinating with supervisors to meet daily production requirements.

Conducting trial and design assessment of new development.

Attainments:

Defined and established machine parameters for higher productivity and optimal performance on Machines like Windsor, Engel and Mafatlal-Niigata from 100 to 300 tonnes.

________________________________________TRAININGS ATTENDED

Basics of Operation Optical Media Manufacturing Machines at 4M & Netstal, Switzerland.

Machine Operation Training cum Machine Qualification at Sternfels, Germany.

10-Days Vigorous Training cum Production Activity on Mafatlal Niigata Machine (NN 300) with guidance of Core Health Care Ltd. at Indo-German Tool Room, Ahmedabad.

Successfully completed Training of Trainers, Training for ERP implementation and on QC Tools.

Successfully completed Green Belt training & involved in completion of 3 Projects including 1-Black Belt – Certified by Motorola.

Attended various Managerial In-house trainings like Influencing, Conflict Resolution, Communication Skills.

________________________________________ACADEMIA

Pursuing MBA from IMT, Ghaziabad

1996 PG Diploma in Plastics Processing Technology from Central Institute of Plastics Engineering & Technology, Ahmedabad.

1995 B.Sc. (Chemistry, Botany, Zoology) from MDS University, Ajmer, Rajasthan.

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SKILLS & BEHAVIOUR:

I possess the required skills to execute my responsibilities effectively as given below and consistent behaviour though learning and improvement never ends:

Analytical and Troubleshooting skills

Find out solution to the problems

Product development and Application skills

Consistent and focused working

Patience working

Conviction to achieve results and passion

Systematic and develop relevant documents

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PERSONAL DETAILS

Date of Birth : 21st January 1975

Linguistic Abilities : English and Hindi

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