Manager Production, Casting purchase follow up engineer - Sri Vari Ferrocast Private Limited - Coimbatore, India
(2020-11)
Dual role combining purchase engineer and production manager responsibilities.
- Analyze new product orders to determine manufacturing feasibility, considering technical, material and resource constrains
- Collaborate with development teams to ensure prototypes are manufactured successfully in the workshop or with vendor workshop
- Plan and arrange for the procurement of necessary materials based on the production plan
- Collaborate with suppliers to ensure material availability align with production schedule
- Allocate production jobs to vendors and suppliers according to the production plan
- Negotiate terms with supplies, focusing on cost, delivery timelines and quality assurance
- Maintain clear records of agreements, quotations, and contracts to avoid repetitive errors and vendor defaults
- Make proactive decisions regarding future requirements based on the evolving production plan
- Anticipate potential production bottlenecks and take corrective action in advance
- Prepare and ensure timely dispatch schedule for all finished parts
- Coordinate with relevant stakeholders to meet weekly dispatch schedule
- Maintain regular communication with suppliers to ensure the timely delivery of materials and components
- Follow up on any issues related to supplier performance, quality, or delivery timelines
- Generate the daily melting schedule, ensuring proper preparations are made before pouring with process control in melting
- Perform relining and sintering of induction furnace and operation of the induction furnace
- Manage the workmen for achieving the periodic production targets in Grey iron/S.G.iron foundry
- Plan and execute operations like Induction Melting, Charge calculation, melt composition adjustment
- Maintain the Quality and quantity of mould and moulding sand, ensuring sand plant activities
- Ensure regular preventive maintenance of machine to ensure smooth running in the shift, guiding operator in resolving machine problem at the time of breakdown
- Plan BOM and raw material procurement schedules
- Identify scope for modifications in process for controlling and reducing costs per unit
- Handle operations for improvement in existing products based on market trends and requirements
- Execute cost saving techniques and modifications to achieve substantial reduction in O&M expenditures and work within the budget
- Improve Quality / Productivity / Reliability at manufacturing with continual improvement
- Ensure compliance to quality while performing various activities
- Monitor discipline at the shop floor for an accident free and safe work culture
- Handle shift production and TPM related activities and supervise preventive maintenance
- Maintain machine efficiencies by attending to and resolving machine breakdowns in shifts
- Extend the development and implementation of technology to improve productivity through 5S implementation
- Prepare process sheet accordingly for each SG casting iron and Rolls, Gray Cast Iron and ductile Iron
- Maintain day wise production schedule, produced report and back log report
- Prepare weekly shift wise and machine wise manpower planning report
- Coordinate Quality Control, Purchasing and marketing Person to achieve Perform to schedule goals
- Monitor Shop Floor housekeeping, maintain open communication with employees and work with employees to mutually resolve problem to enhance morale
Production Engineer - Ratnadeep Castings - Pune, India
(2020-11 - 2022-01)
Focus on production process control and quality management.
- Arrange Incoming inspection of raw materials and approval and issue to production dept
- Follow up process control at coreshop, sand plant, moulding shop, melting shop, pouring, fettling and inspection stages
- Control of green sand additives and defect control
- Conduct daily rejection meeting to find out rejection and to control in process
- Address Internal Non-conformance issue and follow up
- Attend customer side meeting to discuss quality issues and convey it to production team to avoid future problems
- Execute CAPA for non conformity observing and ensuring that they are properly followed in process
- Arrange layout inspection of castings and giving reports to customer
- Maintain knowledge of PPAP, CONTROL PLAN, FMEA, PROCESS FLOW DIAGRAM
- Maintain 5S throughout the Department
- Conduct regular process audit for Process improvements and cost reduction
- Attend internal audits
Engineer Quality - Vasanthi foundry - Coimbatore, India
(2018-07 - 2020-10)
Quality assurance and process control responsibilities.
- Arrange Incoming inspection of raw materials and approval and issue to production dept
- Follow up process control at coreshop, sand plant, moulding shop, melting shop, pouring, fettling and inspection stages
- Control of green sand additives and defect control
- Conduct daily rejection meeting to find out rejection and to control in process
- Address Internal Non-conformance issue and follow up
- Attend customer side meeting to discuss quality issues and convey it to production team to avoid future problems
- Execute CAPA for non conformity observing and ensuring that they are properly followed in process
- Arrange layout inspection of castings and giving reports to customer
- Maintain knowledge of PPAP, CONTROL PLAN, FMEA, PROCESS FLOW DIAGRAM
- Maintain 5S throughout the Department
- Conduct regular process audit for Process improvements and cost reduction
- Attend internal audits
Production and Quality engineer - Lambodara Automotives Pvt. Ltd - Coimbatore, India
(2011-06 - 2018-07)
Newly launched project of green sand and Co2 process foundry, manufacturing of automotives parts and supplying to branches in US, Canada, Brazil and China.
- Attend monthly production meeting and collect the order schedule
- Schedule the order on priority basis and prepare the monthly and weekly planning
- Conduct the department meeting and issue and plan for production on 1st of the month
- Plan and arrange for the materials and raise the indent as per the schedule
- Hold daily meeting with the supervisors for the output and the issues on the shop floor and immediate action for the rectification
- Allocate daily work and reports and provide feedback updating to Directors
- Arrange for the meeting and collect the ideas and feedback from the shift supervisors and implement the betterment
- Prepare work instructions for new process, reviewing and updating as per ISO Standards
- Attend ISO Audits
- Achieve the production schedule and target
- Calculate cost and review periodically
- Review and Approve Trail card data for new development parts
- Conduct the inspection in the online work
- Perform random quality inspection and the output as per the standards
- Take new projects for process development
- Analyze Target achievement drawback and take necessary corrective action
- Achieve the quality of the production below 2% of the foundry rejection
- Verify Raw Materials quality and the test reports verification and approval
- Prepare and conduct weekly and monthly performance report
- Verify Chemical and Mechanical lab activity results
- Maintain responsibility for Sand plant activities and control of sand properties
- Address Internal Non-conformance issue and follow up
- Prepare data's for daily rejection meeting
- Perform Rejection analysis like part wise and make the corrective action
- Conduct Inline random inspection of the work and make inspection reports systems
- Submit daily reports of the works to be verified
- Monitor Machineries with periodically maintenance to avoid the work interruption
- Perform Calibration for measuring instruments
- Conduct Week end preventive maintenance
- Ensure Zero break down
- Collect and approval the documents from the shift supervisors for the material request
- Maintain Production documents like Log Sheet, ISO documents, rejection report
- Maintain Maintenance record for individual machine history
- Maintain Preventive maintenance log sheet for all machineries
- Submit daily reports to HOD
- Conduct meeting and prepare the minutes of meeting
- Reduce the Cost Control
- Plan and submit fund request from materials to wages and well beings
- Hold daily meeting with company directors task preparation and follow up on time updating to the directors
- Monitor Housekeeping as per 5S
Production Supervisor - Shanthi Gears Pvt. Ltd - Coimbatore, India
(2010-06 - 2011-06)
Leading green sand and Co2 process Foundry Manufactures of High Quality Grey Iron Castings and Ductile Iron Castings, Capable of 300 tons good castings per month. Specialized in Manufacturing Gears and Gear boxes with machined and assembled.
- Oversee Casting produced in induction furnace as per chemical composition according to required Customer Specifications
- Make Daily and Weekly Planning as per the Order Priority
- Submit the Material requirements to the Stores by getting approval from the HOD as prior as possible as per the Work planning
- Maintain the records of the section workers and to provide safety equipment also arranging those wages for sub contractors and other benefits at right time
- Follow up with the team members in all sections to achieve target
- Make the sample casting and to send it for approval with the specification and Dimension, inspection report
