Lean Manufacturing Coach - Solid Inspire Inc - Bangalore
(2024-08 - 2024-10)
Working for Turkish- APO project on creating a road map for Industry 4.0 implementation in their Modal factories. Acting as a bridge between Lean consultants in Turkey Model factory and Digital Transformation consultants in Solid Inspire, South Korea.
- Created Assessment Matrix template in Excel as per SIRI framework and Identified 4 Priority Dimensions after calculating their Impact Value by referring to Prioritization Matrix documents given by the Singapore Economic Development Board
- Evaluated Lean Maturity of SME's and Model factories across 4 different cities in Turkey namely Ankara, Konya, Bursa & Kayseri
- Identified Excess Inventory as the prevailing problem in 8 SME's visited and established Inventory Turns metric to monitor them, so that they can be eliminated by establishing Pull signals
Senior Lean Manufacturing Consultant - Gemba Concepts Pvt Ltd - Bangalore
(2023-07 - 2023-12)
Trained shopfloor and management employees on 5S, guided the team during implementation, resulting in 18% floor space savings & 7% lead time reduction. Successfully completed manpower Optimization project for the aforesaid client by 30%. Developed and trained quality department personnel on writing "Problem Solving A3" for defects (client Arvind Mills Ltd.) Developed training material on proposal presentations on Sales & Operation Planning as per APICS - CPIM standards.
Lean Manufacturing Consultant - Lean On Us Pvt Ltd - Bangalore
(2022-10 - 2023-04)
Defined and established performance measurement system. Co-created Mission & Vision statement, Set core values. Established Strategy Map, Objectives, Measures, and Targets using the Balanced Score Card approach.
- Determined safety stock, re-order point, lead time demand, economic order quantity levels for products in stores resulting in reduced inventory holding cost by 28% annually, thereby saving INR 1.3 crores through Inventory Optimization project for client 'Micro Pack Pvt Ltd' with turnover of INR100 crores, 500 employees
- Completed Time and Method study for secondary operations in injection molding plant for client 'Precision Compaid Molding Pvt Ltd'. Defined SOP as per International Labor Organization (ILO) standards, established rating factor and relaxation, contingency & special allowances for secondary operations resulting in productivity improvement by 15%
- Generated demand forecasting models to predict future demand trends for 3 years period, utilizing exponential smoothing, weighted average & holt winter technique, also taking into consideration seasonality, level, trends in past data for client 'Manak Petroleum Pvt Ltd'
- Determined Trigger Point for Kan-Ban implementation using Signal Kan-bans for Batch Producing Processes such as Injection Molding division of Tier 2 Automotive OEM, leading to increased variants from 7 to 11
- Defined and created bench mark for Lean Management System and its elements like Leader Standard Work, Visual Control, and Daily Accountability Process templates for the Daily Management of the Production process
Process Engineer-Lean Manufacturing - Alstom Transportation India Pvt Ltd - Bangalore
(2020-02 - 2020-12)
Lean Principal Coach and internal trainer, successfully trained & Certified 150+ employees on Lean fundamentals, SMED, Standard work and Value Stream Mapping (VSM). Developed training content for internal training program on lean manufacturing, on tools like Jidoka, OEE, 5S, Kan Ban, VSM, PDCA, Takt time, Theory of Constraints, A3 method, Gemba, Kaizen, TPM, Root cause Analysis etc.
- Creating Design for Assembly Analysis Worksheet (DFMA) and Work Instructions using tools like Visio
- Worked on (MOST) Maynard Operation Sequence Techniques to fix work content for assembly processes
- Lead Product Development value stream projects (PDVSM), reduce lead time by 3 days for PBOM creation in Delmia
Associate Process Consultant-Lean Manufacturing - Tech Mahindra India Pvt Ltd - Bangalore
(2018-04 - 2019-05)
Worked as Process Consultant for client TERUMO-BCT health care manufacturing facility in Ho Chi Minh City, Vietnam.
- Designed Supermarket for - C200 channel sub assembly line, calculated optimum number of movable racks to store vent and sample bags, Coordinating Ramp-up Plan for T4 Machine (RF Welding and Press)
- Designing PI and PW Kan-Ban cards to operate between TRIMA Line, Ware House and C200 Cell
- Calculating Pitch and Pitch Interval and Designed Heijunka Board for scheduling Channel Sub assembly parts, operating Vent & Sample Bag machines & gathered consensus on Level Pull in manufacturing at leadership level
Advanced Engineer- Purchase Order Management - Altran Technologies India Pvt Ltd - Bangalore
(2013-01 - 2017-02)
Worked for Client by name Ichor Systems-USA.
- Creating and issuing purchase orders, ensuring accuracy and completeness
- Verifying specifications, prices, and payment terms
- Monitoring and expediting orders to ensure timely delivery
- Managing purchase order records and ensuring compliance with company policies
Senior Engineer- Lean Manufacturing - TE Connectivity India Pvt Ltd - Bangalore
(2011-07 - 2012-07)
As Process Engineer oversaw operation excellence initiative for the connector and mod-jack line.
- Completed Line Balancing project for RJ45 connector line & increased output per shift from 8345 to 12634 parts thereby contributing to 44% increase in line revenue
- Initiated & completed the Single Minute Exchange of Die (SMED) in stamping unit to reduce die setup time by 33.7%
- Introduced best practices in the workplace & completed value stream mapping for the smart card assembly line and successfully reduced non-value-added (NVA) time by 26%
- Designed U-cells to facilitate flow throughout the value stream, optimized number of operators, & increased productivity per operator by 17.8%
- Designed and Implemented Kan-Ban Cards and Heijunka Board for handling replenishment and flow of smart card contacts. Analyzed processes and suggested improvements to reduce non-value-added activities using spaghetti diagram. Trained shopfloor personnel on Tyco Electronic Operating Advantage, including 6 foundation tools & 11 additional tools
Systems Engineer- First Article Inspection Analyst - Tata Consultance Service Ltd - Bangalore
(2010-12 - 2011-07)
In-charge of First Article Inspection (FAI) report, review and approval process for the client by name Applied Material India.
- Reviewed FAI submitted worldwide, in compliance with GMRM-2-60.1 document norms
- Read 2D & 3D drawings while submitting the FAI Report, familiar with ASME Y 14.5M GD&T standards
- Responsible for BOM verification, Vendor status verification and Receipt control adjustment, using SAP and Oracle applications
- Lead monthly reports generation, progress update for management review
Senior Engineer- Production & OpEx - Dover India Pvt Ltd - Chennai
(2009-10 - 2010-12)
Production In-charge of OPW FC cell in Chennai facility, monitored daily production planning & control, Overlooked Planning & Inventory management for products (CNG nozzles, receptacles and breakaways). Met daily & monthly targets as well as quality objectives, as per customer demands. Developed SOP and test instructions for products.
- Responsible for TUV ECR R110 certification for CNG Cell and UL Certification for above the ground nozzle line
- Carried out installation & operation of machines such as Yamato Vacuum Dryer, Bauer Compressor, EFD Performus III Fluid Dispenser, Edward RV5 vacuum Pump, Ostling Laser marking machine, Flow tester, Trimos height gauge, CMM
- Increased production capacity from 24000 to 66000 nozzles/line/year, by creating continuous flow in nozzle line and reducing seven deadly wastes (Lean Manufacturing), implemented Kaizen results, thereby increased profits by over $0.5 million/annum
Executive-Industrial Design - Kennametal India Ltd - Bangalore
(2007-07 - 2009-05)
