Pradeep Kumar

Lean Consultant for EMS industries, mobile accessories manufacturing etc

Greater Noida1500 INR/hourMember since 14 April 2026

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About

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.

Experience

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.