Sathish Kumar
Manager Production – Body in White (BIW)
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About
Diploma Mechanical Engineer with 18 years of extensive experience in production and Manufacturing in the field of Automotive WELD SHOP. A Mechanical Engineer with 18 years of extensive experience in WELD SHOP managing manufacturing operations encompassing production Engineering.
Optimized Shop Floor
Layout, Line Balancing, Job Allocation Efficiency & Manpower Requirement Calculations by Design Standard Time. Responsible for planning layouts after initial process study for various assembly processes and implementing Material Flow Management concepts in Body Shop.
Achieve
Cycle time and close all concerns related to Quality, Safety, Ergonomics and Workability Fatigue for new models.
Experience
Manager Production – Body in White (BIW) at YSI AUTOMOTIVE PVT LTD (2021-03 – Present)
Tier 1 Vendor of Auto OEMs like HYUNDAI, MOBIS & Daimler major BIW parts and trim assembly parts. As a Production leader of the Production Team, accountable for meeting the department production and quality goals, as well as playing a key role in meeting the company wide profitability and customer satisfaction goals.
- Daily meeting conduct with line leader and Engineer production plan vs. actual achievement
- Daily quality Concern Cascade in down the level
- Daily review With PPC plan achievement status
- Reducing the NVA in the process by Eliminating form four motion principles
- Doing continuous Improvement in Safety, Quality, Delivery, Cost, & Morale
- Monthly Review with Skill matrix
- Daily meeting with GM pervious day performance review
- Daily meeting with MD and Plant head Quality and Delivery performance review
- New model Design review with Development team
- Planning for preventive maintenance
- Knowledge in robots handling, setting welding parameters
- Monthly Line leader performance review in term of Attendance and Productivity
- Weekly production Plan vs. Actual production review
- Plan and prioritize operations to ensure maximum performance and minimum delay
- Estimate costs and prepare budgets
- Weld Carrier Assy Line 37 UPH to 40 UPH achieved by robot unnecessary movement and job allocation balance
- In Co2 welding all model weld length taken, excess weld removed as per standard and co2 wire consumables reduced for cost saving
- Co2 weld correction time per shift 2 hours to 45 minutes reduced
- Cost reduction for raw materials reduction around 10 lakhs/year
- Manpower reduction 105 to 92 manpower reduced
- In Projection 4 spot weld in 4 strokes improved in single stroke in 4 spot weld 110 UPH to 440 UPH increase
- Cap tip spot dressing quantity increased to reduce tip usage
- Brass shank holder, Robot torch reworked and reused for cost saving
- Co2 line stage split up implement for UPH increase
SR. Engineer Production at Renault Nissan Automotive India Pvt. Ltd. (2010-05 – 2020-05)
Joint venture company of two big giants of car manufacturer. Manufacturing NISSAN (Micra, Sunny, Terrano, Evalia), DATSUN, RENAULT (Duster, Lodgy, Pulse, Fluence).
- Reduce waste motion through the proper design of the work environment
- Responsible for optimum utilization of man hours
- Making action plan for achieving business objective of productivity, quality & cost reduction
- Responsible for monitoring of daily in house quality issues
- Responsible for corrective action implementation & effectiveness monitoring
- Responsible for training & educating workmen for creating awareness for quality, 5S & effective work methods
- Responsible for conducting training (OJT) for team members
- Responsible for monitoring & improving operator skill matrix
- Implementation of Error Proofing (POKA-YOKE) system in jigs, fixtures & machines
- Improving part quality in tryout stages by taking corrective action & preparing counter measure reports
- Identify areas of improvements to reduce operator fatigue
- Received Best Genba Kanri (Shop Floor) Management award (First Place)
- Received Best 5S Zone Rolling trophy
- Involved in JPH improvement activity
- CFT formation for achieving Quality concerns
- Involved new project activities (Head count calculation, Layout Facilities)
Asst. Engineer in Production Dept. (WELD SHOP) at Hwashin Automotive India Pvt Ltd (2007-02 – 2010-05)
Korean MNC that supplies sheet metal body parts and chassis parts to automobile giant Hyundai motor India pvt ltd. Hwashin has its manufacturing units all over the world.
- To train the team members by means of establishing standardized work chart
- Reducing the NVA in the process by Eliminating form four motion principles
- Doing continuous Improvement in Safety, Quality, Delivery, Cost, & Morale
- Rework instruction preparation & training to operators
- Machine Start up checks sheet preparation and updation
- Quality checking procedure & checking instruction preparation
- Control item list preparation
- Monitor and Target TAKT time achievement by implementing kaizens
- Kaizen co-ordination with spec sheet
- Making easy process environment for operator to work using method study
- Achievement of Best productivity line (COWL BAR & FUEL TANK)
- Involved in CFT for new model development
- Involved in Head count reduction through KAIZEN
Apprentice Training (WELD SHOP) at Thyssenkrupp JBM India Pvt Ltd (2005-12 – 2006-12)
Supplies sheet metal body parts and Weld parts to automobile giant FORD India Ltd.
Education
Diploma in Mechanical Engineering – Bhaktavatsalam polytechnic college (2002 – 2005)
