NIkhilkumar Mane

Assistant Production Manager with 14 years of progressive experience in heavy press shop as well as light press shop, automotive chassis, BIW, welded assemblies. Proven expertise in greenfield & brownfield projects, new product launches, press shop operations, productivity improvement, and cost optimization. Strong & decisive leadership, collaboration skills, consistently delivering productivity, zero PPM, improved OEE, and cost savings.

Asst. Manager – Production, Manufacturing Engineering & Launch Leader at BENTELER AUTOMOTIVE INDIA PVT LTD (2023-08 – Present)

• Lead manufacturing engineering and launch activities for chassis and structural components supplied to customers like MSIL, VW & HONDA.
• Manage post-project finalization activities, ensuring smooth transition from project planning to execution and operational readiness.
• Finalized manufacturing processes, equipment specifications, and technical requirements in collaboration with global engineering teams.
• Evaluate and finalize supplier nominations from a technical and capability perspective, ensuring alignment with project requirements.
• Lead equipment design finalization and technical coordination with suppliers after order placement, in collaboration with subject-matter experts.
• Monitor project progress, milestones, and deliverables through regular coordination and follow-up with equipment suppliers.
• Conduct supplier visits and technical reviews to monitor equipment development, fabrication, testing, and project progress against agreed timelines.
• Coordinate and supervise civil works and infrastructure activities required for successful project implementation.
• Coordinate equipment installation, commissioning, and start-up activities at the plant in collaboration with suppliers and cross-functional teams.
• Manage and maintain project execution documentation, including technical records, approvals, equipment documents, and commissioning-related documentation.
• Lead the project handover to Production and Maintenance teams, ensuring completion of documentation, operational readiness, and smooth transition to routine operations.
• Drive launch planning, prototype builds, vehicle build support, and handover to project teams as per customer requirements.
• Lead takt time analysis, manpower planning, line balancing, and bottleneck elimination through time & motion studies.
• Implement poka-yoke, corrective actions, and contingency plans to eliminate internal and external quality risks.
• Manage SAP work centers, routings, EBOM, and production versions.
• Act as a technical bridge between engineering, operations, suppliers, and leadership.
• Drive continuous improvement initiatives delivering cycle time reduction, cost savings, and productivity gains.

Sr. Engineer – Production (Press Shop) at MUNGI ENGINEERS PVT LTD (2020-11 – 2023-07)

• Lead and support production operators, subordinates, and shop-floor personnel to achieve daily production targets while maintaining quality and safety standards.
• Manage day-to-day production planning and scheduling based on production requirements, manpower availability, machine capacity, and delivery priorities.
• Drive execution of production targets and operational KPIs, ensuring timely achievement of targets set by management.
• Plan and optimize manpower allocation and deployment across production activities to maximize workforce utilization and productivity.
• Lead the IPQC (In-Process Quality Control) pillar, driving process quality, defect prevention, and adherence to defined quality standards.
• Implement and monitor JH (Jishu Hozen/Autonomous Maintenance) pillar activities under TPM, promoting operator involvement in equipment care and improving machine reliability.
• Identify and implement continuous improvement initiatives to enhance productivity, process efficiency, quality, and overall equipment effectiveness.
• Focus on production cost optimization and productivity improvement through efficient utilization of manpower, materials, machines, and process resources.
• Lead, develop, and monitor the production team, fostering accountability, teamwork, operational discipline, and performance improvement.
• Ensure strict compliance with health, safety, and workplace standards, promoting a safe and disciplined shop-floor environment.
• Conduct performance reviews of subordinates and operators, identify skill and competency gaps and coordinate targeted training and development programs.

Sr. Engineer – Production (Heavy Press Shop) at AUTOCOMP CORPORATION PANSE PVT LTD (2017-11 – 2020-11)

• Manage day-to-day production operations to achieve planned output, quality, productivity, and delivery targets.
• Execute shift-wise production planning and scheduling based on production requirements, manpower availability, machine capacity, and priorities.
• Drive achievement of daily and shift-wise production targets, ensuring timely completion of the production schedule.
• Manage the IPQC (In-Process Quality Control) pillar, ensuring adherence to process quality standards and effective defect prevention.
• Implement and monitor JH (Jishu Hozen/Autonomous Maintenance) pillar activities under TPM to improve equipment reliability and operator ownership.
• Identify and implement continuous improvement initiatives to enhance production efficiency, process capability, productivity, and quality.
• Optimize production costs and resource utilization while maximizing productivity through effective utilization of manpower, machines, and materials.
• Lead, develop, and monitor the production team, driving performance, discipline, teamwork, and achievement of operational goals.
• Ensure strict compliance with health, safety, and workplace standards, maintaining a safe and disciplined shop-floor environment.
• Monitor operator performance, identify skill gaps and training needs, and support employee development through targeted training and coaching.

Sr. Engineer – Production (Press Shop) at SPARK GROUP OF INDUSTRIES (2014-03 – 2017-10)

• Manage monthly, weekly, and daily production planning, machine capacity, manpower allocation, and shift scheduling to achieve production, quality, and delivery targets.
• Monitor and improve OEE, Plan vs. Actual performance, downtime, and production losses through root-cause analysis and effective corrective actions.
• Coordinate Preventive Maintenance and in-process quality control activities to improve equipment availability, process stability, and product quality.
• Implement Kaizen and continuous improvement initiatives to enhance productivity, reduce losses, optimize processes, and encourage operator involvement.
• Lead and develop production teams, ensuring compliance with safety and environmental standards while providing training and driving operational excellence.
• Reduce scrap and rework costs through process improvements and CAPA implementation.

Production Supervisor - (Laser cutting & Bending) at AURA LASER FAB PVT LTD (2012-12 – 2014-03)

• Manage shift-wise production planning, manpower allocation, and day-to-day operations, ensuring material flow, production output, and dispatch schedules were achieved as per customer requirements.
• Supervise shop-floor processes, equipment, manpower, and resource utilization, maintaining 5S, process controls, production standards, and accurate shift-wise production reporting.
• Implement and monitor JH (Jishu Hozen) activities under TPM, driving operator involvement, equipment ownership, process stability, and continuous improvement.

Bachelor of Technology in Mechanical – RIT, Islampur, Sangli (2012)

Diploma in Mechanical Engineering – RIT, Islampur, Sangli (2010)