Sunil Ingole

Dynamic and result-driven manufacturing professional with 26+ years of experience in CNC/VMC/HMC machining, planning, team management and plant operation. Proven expertise in streamlining production processes, cost reduction, OEE improvement, and zero-defect delivery. Adept at leading cross-functional teams and ensuring adherence to quality and safety standards.

An effective leader with distinguished abilities in directing, leading, Training & motivating a large workforce. Monitoring plant efficiency through TPM (PQCDSM). Hands on experience -CNC (Proteck, FMS, ACE Micromatic), VMC (OKK, BFW, Hyundai, AMS), HMC SW with twin spindle, HMC BFW, Siemens, Fanuc control, SPM (Facing & centering, Horizontal drilling, Washing), KP bush press, ABS bush press, Keyway broaching, Radial drilling, Hobbing Cooper, Induction hardening GEC, Grinding (HMT, Parisudh), Tempering Furnace, MPI.

Production Head - Poona Forge Pvt. LTD - MIDC Bhosari, Pune

(2023-02)

Team Size: 90+, Machines: 30+ (CNC/VMC/HMC- Fanuc, Siemens control). Customer -Dana Graziano Noida, Sanand, Belgaum, Carraro India Ltd, Ranjangaon, Daimler India commercial vehicle Chennai, Cummins India Ltd, AAM India Ltd, Hendrickson Ltd.

• Lead daily production activities for high-precision components for auto and engineering sectors.
• Increased OEE from 65% to 81% within 2.5 years through kaizen and down time analysis.
• Implemented lean practices and reduced cycle time by 20% across key operations.
• Coordinated with design, quality and maintenance teams to meet monthly output targets.
• Ensured 100% on time delivery with zero customer complaints over 2.5 years.
• Implemented SPC, FMEA and 7QC tools in process audit and problem solving.
• Reduced rejections from 4% to < 1% using root cause analysis and poka-yoke.
• Reduced tool cost by 15% thorough vendor comparison and alternate tool trials.

Production Manager - Radheya Machining LTD - Sanaswadi, Pune

(2019-09 - 2023-01)

Team Size: 100+, Machines: 45+ (CNC/VMC/HMC-Fanuc, Siemens control). Customer - Parkar Hannifin corporation USA, Eaton Hydraulics Pimpri Pune, Mahindra & Mahindra, GE, Carraro India, JCB. Types of machine- CNC, VMC, HMC, Centerless Grinding, Cylindrical Grinding m/c, welding m/c, Broaching Machine, M1TR.

• Handled operations of CNC turning and VMC machines for export components.
• Lead daily production activities for high – precision components for auto and engineering sectors.
• Implemented fixtures design changes to improve accuracy and reduced setup time.
• Implemented lean practices and reduced cycle time by 20% across key operations.
• Coordinated with design, quality and maintenance teams to meet monthly output targets.
• Developed and trained 25+ operators for CNC and VMC programing.
• Implemented SPC, FMEA and 7QC tools in process audit and problem solving.
• Reduced rejections from 4% to < 1% using root cause analysis and poka-yoke.
• Reduced tool cost by 10% thorough vendor comparison and alternate tool trials.

Deputy Manager - Bharat Forge LTD

(2005-09 - 2019-08)

Line Handled as Deputy Manager in production line & spear heading steering knuckle line. Types of machine- CNC, VMC, HMC twin spindle, Bush press, Broaching machine, Magna flux Washing. CUSTOMER – Dana Spicer USA, Meritor USA, Automotive Axles.

• Responsible for process planning, job setting, tool selection for HMC/ VMC.
• Conducted time study and implemented Takt-time based planning.
• Worked as a shift in-charge.
• Handled operations of CNC turning and VMC machines for export components.
• Lead daily production activity for high precision components.

Officer Machine shop - Amtek Auto Ltd, was Ahmednagar Forging LTD. - Chakan

(1997-04 - 2005-08)

Types of machine - Press m/c, Grinding m/c, Hobbing, SPM drilling, Radial drilling, Broaching, Induction Hardening, Milling, Lathe. CUSTOMER –TATA Motors, Mahindra & Mahindra. Types of dept handled - Production, PPC, QA. Reporting to- Sr. Manager.

• Man power Handling
• Measurement inspection m/c-linear height gauge, surface finish, Digital Height gauge, Hardness testing m/c.
• Monthly plan, customer ppm, in house ppm, pm plan, inventory control,
• Manpower cost, cost of poor Quality, team building, 5 ’S’ TPM, Internal & External Audit plan, and actual NC Closing, Training plan and actual, Visual indicator alert.
• Yearly plan & monitoring, monthly review meeting.

Trainee Engineer - Ahmednagar Forging Ltd - Chakan

(1995-04 - 1996-03)

BS - Manufacturing Engineering - BITS Pilani

Diploma - Mechanical Engineering - MSBTE Mumbai

SSC - Nagpur Board