Pradeep Kumar

Sr. Engineer Production/Operations candidate with 12+ years of experience in high-volume

EMS/mobile manufacturing, specializing in FATP assembly, Lean implementation, and production management. Proven track record of managing 400+ shop-floor personnel, improving OEE, FPY, and throughput, and driving cost reduction through Lean, Kaizen, and data-driven decision making.

Experienced in NPI ramp-up, PFMEA, control plans, and CAPA/8D problem solving, with strong exposure to MES (Athena), ERP systems, and digital production dashboards (Power BI). Adept at production planning, line balancing, and cross-functional coordination to achieve daily production targets, quality KPIs, and customer delivery commitments.

Technical & Lean Manufacturing Tools & Systems:

FATP Mobile Assembly & Testing, Production Planning & Control (PPC), Capacity Planning, Line Balancing & Takt

Time Design, OEE, FPY, DPMO, PPM & Yield Improvement, Lean Manufacturing (5S, Kaizen, VSM, Kanban, JIT,

Poka-Yoke, Jidoka), Six Sigma (DMAIC, CAPA, Yellow Belt), PFMEA, Control Plans & Process Validation, Root Cause

Analysis (8D, 5 Whys, Fishbone, A3), Statistical Process Control (SPC) & Control Charts, MES (Athena) & ERP

Systems (SAP), Production Dashboards (Power BI, Advanced Excel), Robotics Programming (Yaskawa, Fanuc) &

Automation, AOI, Clean room standard, Quality Management Systems (ISO 9001) & ESD Controls in EMS, ShopFloor Management & Shift Handling, Manpower Planning & Line Staffing, Daily Work Management (DWM) & Tier

Meetings, Material Flow Optimization & Inventory Control, WIP Reduction & Single-Piece Flow Implementation,

Throughput, Cycle Time & UPH Improvement, NPI Ramp-Up, ECN/ECM Implementation, Cost per Unit Reduction

& Productivity Improvement, Safety, 5S, Ergonomics & Compliance, Value Stream Mapping, System Improvement

Process, Lean Methodology

Soft Skills & Leadership:

Team Leadership & Supervision, Cross-Functional Coordination (Production, Quality, IE, Maintenance, Planning),

Analytical & Critical Thinking, Problem Solving & Data-Driven Decision Making, Gemba Walks & Visual

Management, Training, Coaching & Skill Development, Stakeholder Communication & Reporting to Management,

Adaptability in High-Pressure, High-Volume Environments, Continuous Improvement Mindset.

OPPO MOBILES INDIA PVT. LTD.

Sr. Production and Lean Engineer

October 2024 – Present

• Production Planning & Scheduling, Material Flow Optimization, Inventory Control, Shop-Floor

Management, Shift Handling, Daily Work Management (DWM), Tier Meetings, Capacity Utilization

• Managed end-to-end production operations high-volume FATP operations for mobile assembly,

managing 350+ personnel and 8 engineers to achieve daily output of 55,000+ mobile units while maintaining strict quality and safety standards.

• Improved OEE of critical assembly lines by 8–12% through bottleneck analysis, SMED implementation,

and preventive maintenance planning in collaboration with Maintenance and Industrial Engineering.

• Reduced in-line defects and rework by 20–30% by driving structured 8D and CAPA for top recurring issues and monitoring PPM trends through SPC and MES dashboards.
• Led daily production review (DWM/Tier meetings) with cross-functional team members, tracking KPIs such as output, FPY, absenteeism, and material shortages, and driving quick containment and long-term corrective actions.
• Coordinated NPI and ECN/ECM activities with PE, and Quality to ensure process capability, PFMEA completion, control plan implementation, and smooth ramp-up to mass production volumes.
• Optimized material flow and line layout using Lean tools (VSM, process diagram, POU, LCIA), reducing material handling time and WIP levels while improving safety and ergonomics.
• Handled shift-level shop-floor management for 350+ operators and engineers, ensuring adherence to production plan, work instructions, 5S, ESD controls, and safety guidelines.
• Spearheaded Lean Manufacturing initiatives, conducting 15+ Kaizen events and implementing 5S, Kanban,

and VSM, resulting in a 43% increase in Production Cycle Efficiency (PCE)—from 3.5% to 5%.

• Manufacturing & Operations: High-Volume EMS Assembly Line Management, Production Planning &

Control (PPC), Capacity Planning, Manpower Planning & Line Staffing, Line Balancing & Takt Time Design

• Metrics & KPIs: OEE Improvement, FPY Improvement, Rejection & Rework Reduction, DPMO & PPM

Control, Yield Management, Cost per Unit Reduction

• Quality & Problem Solving: 8D Problem Solving, 5 Whys, Fishbone (Ishikawa), CAPA Management,

Control Charts, Process Capability, FMEA (PFMEA/DFMEA)

• Systems & Tools: MES (Athena) & ERP (SAP/Oracle), Production Dashboards (Power BI, Excel), SPC Tools,

AOI & ICT Systems.

OPPO MOBILES INDIA PVT. LTD.

Production Engineer

July 2019 – October 2024

• Managed day-to-day operations of mainline mobile assembly in a high-volume EMS environment,

supervising 180+ operators and ensuring adherence to daily production, quality, and delivery targets.

• Improved UPH from 360 to 400 units on mainline assembly by optimizing line balancing, takt time, work allocation, and minimizing micro-stoppages, resulting in higher throughput without additional manpower.
• Reduced in-line defect rate from 0.80% to 0.50% through structured root cause analysis ( 5 Whys,

Fishbone ) and implementation of Poka-Yoke, standardized work, and enhanced operator training.

• Executed production planning, line loading, and manpower allocation across multiple lines, ensuring optimal utilization of 180+ shop-floor personnel and on-time completion of shift-wise production plans.
• Monitored OEE, FPY, rejection and rework trends using shop-floor data and reports, driving corrective and preventive actions (CAPA) for top recurring issues to stabilize key processes.
• Supported NPI builds and model ramp-ups on mainline assembly in coordination with Production

Engineering, Quality, and Planning, ensuring process readiness and smooth transition to mass production.

• Implemented Lean and 5S practices (visual management, standardized work, Poka-Yoke) on the line,

improving workplace organization, safety, and compliance with ESD and quality standards.

• Conducted on-the-job training and upskilling for operators on work instructions, critical quality checkpoints, and safety guidelines, reducing handling-related defects and human errors.

CAPARO MARUTI INDIA LTD.- Tier-one sheet metal weld assemblies and closures supplier to MSIL,

Production Engineer

August 2014 – June 2019

Sheet Metal Welding Process Expertise

• Robotic Welding (Spot, MIG, Projection)
• Robotic Programming & Integration: Programmed and integrated robotic welding systems (FANUC, ABB,

Moto man, KUKA) for high-volume production lines, utilizing online teaching and offline programming to optimize weld paths.

• Process Development: Developed, validated, and optimized robotic welding procedures (MIG, Spot) to ensure weld quality, penetration, and strength met stringent customer specifications.
• Fixture Design: Spearheaded the design and modification of welding fixtures and jigs for robotic cells to ensure repeatability, precision part location, and minimize distortion.
• Troubleshooting: Diagnosed and resolved complex issues in robotic welding systems, including mechanical, electrical, and software faults, to minimize downtime and maintain production schedules.

Specialized & Manual Welding Processes

• Resistance Welding: Managed spot and projection welding processes, including setup of PSW and IT guns, parameter optimization, and troubleshooting of weld controllers to ensure consistent nugget formation.
• MIG Welding: Established and monitored MIG welding parameters (voltage, wire feed speed, gas flow)

for carbon steel and stainless-steel assemblies, addressing defects like porosity and spatter.

• Procedure Specifications: Prepared and maintained Welding Procedure Specifications (WPS) and

Procedure Qualification Records (PQR) in compliance with AWS D1.1 or other applicable codes.

EDUCATION

 B. Tech (Mechanical/Production Engineering)

2014 | Punjab Technical University (PTU) – 76%

 12th (CBSE)

G.B.S.S School, New Delhi – 64%

 10th (CBSE)

G.B.S.S School, New Delhi – 78%

CERTIFICATIONS

• Global Lean Fundamentals Certificate
• Six Sigma Yellow Belt
• Project Management Essentials
• Operations Management Certification
• Green Beltin PSP, SW, VSM &Daily Management Modules
• Certification in Prompt Engineering
• Automation Certificate (AutoCAD)
• SOAR - AI to be Aware Program (Microsoft) Recognized by NCVET.