Senior Manager – Industrial Engineering & Operations at A.T.E. Group (2023-05 – Present)
Head – Industrial Engineering & Assembly | Driving group-wide transformation
- Established Industrial Engineering function across Group of companies, standardizing work measurement, costing, and productivity frameworks
- Led Multidepartments: Industrial Engineering (Team Size = 11), Assembly (Team Size = 68), NPD Automobile (Team Size = 04)
- Delivered ₹4–4.5 Cr+ cost savings through cost mechanism implementation, value engineering, and waste elimination
- Improved OEE from 64% to 76% (+12%), increasing effective plant capacity without additional CAPEX
- Designed and implemented cost mechanism framework across BUs
- Reduced throughput time by 21%, improving delivery performance
- Reduced rework by 1.4% and improved first-pass yield, enhancing quality and customer satisfaction, Led ODR (Operator Driven Reliability) program
- Optimized material handling cost by 12% via layout redesign and lean material flow, Process study and product routing in system
- Improved DSI from 94 days to 67 days (129%)
- Implemented VSM, GAMBA, Product costing, MHR, Cost center structure, Work center structure, SMED, Green packaging
- Strategic business plan and Annual business plan
- Led automation & semi-automation projects, achieving 15–20% manpower productivity improvement
- Designed and deployed real-time OEE & work measurement system improving decision-making speed
- Owned CAPEX planning (₹15–18 Cr) with ROI-driven project selection
- Acted as Operations Head, managing cross-functional teams during leadership gap
- Led Greenfield plant layout & future factory initiatives
- CFT project – Vendor development for critical part
- Green field projects – Create new 94 assembly work centers and 48 Machine work centers (New plant)
Manager – Industrial Engineering at Walchandnagar Industries Limited (2018-10 – 2023-05)
Head – Industrial Engineering & Process Improvement
- Led IE & Lean initiatives across Aerospace, Gear, Defense, Nuclear (7 Divisions)
- Delivered ₹65 lakh/year cost savings by implementing 'Integrated real time work booking system'
- Improved resource utilization by 10–15% in Machine, Assembly, Fabrication shop (DMC, VTL, HBM, S-axis)
- OEE improved by 9% and responsible for calculation, monitor & improve OEE
- Led multi-skilling program, improving manpower flexibility and reducing dependency bottlenecks by ~20%
- Reduced throughput time in defense & aerospace projects by ~18%, improving project delivery timelines
- Standardized work measurement system (MOST & Time Study) across plant, improving planning accuracy
- Optimized plant capacity utilization (1.23 lakh hours/month) through IE interventions
- Led union-linked productivity improvement initiatives, aligning workforce output with business goals
- Played key role in high-impact national projects like Gaganyaan & Chandrayaan manufacturing programs
- Delivered multiple CAPEX and efficiency improvement projects (₹1–3 Cr range)
- Improved line balancing and bottleneck management, increasing overall throughput
- New Part Introduction with stages – DR, DV, PV, PMP
- CFT projects - BI, Union agreement, CAPEX, ABP
Industrial Engineer – Assembly, Machine shop, Industrial Engineering at Rieter India Pvt. Ltd. (2011-05 – 2018-09)
Assembly, Machine shop, Industrial Engineering
- Delivered multiple Kaizen and cost-saving projects
- Improved assembly line efficiency by 15–20% using VSM, line balancing, and takt time optimization
- Reduced cycle time across key processes by 10–18%, improving output capacity
- Designed and implemented semi-automation fixtures, improving productivity by ~12–15%
- Led New Product Introduction (NPI) from design validation to mass production for multiple product lines
- Reduced assembly bottlenecks significantly, enabling smooth production flow
- Implemented Lean tools (SMED, Poka-Yoke, Kaizen) delivering continuous cost and quality improvements
- Improved workspace ergonomics, reducing operator fatigue and improving efficiency
- Contributed to plant consolidation & capacity ramp-up projects
- Routing of the Assembly, Poka-yoke, various operations
- Lean manufacturing tool - Kaizen, VSM, SMED, JIT, Poka-Yoke
- CFT team member of project – Capacity Ramp Up, CODO, Consolidate of two plants
- Effectively implemented My Idea Scheme, Implementation of 'One Point Lesson'
- Implementation of single piece flow process using, VSM, Line balancing
- Coordination with local as well as Global team for implementation of new projects
- CAPEX & OPEX proposal preparation & circulation for approval
Trainee Engineer at Pune Instrumentation Pvt. Ltd.
- Supported machine shop operations, improving process discipline, supervision
- Contributed to new product development activities
