Vishal Baviskar

A competent professional with over 24+ years of experience in Plant Management, Manufacturing Operations, Production, Production Planning, Quality Control, Lean Manufacturing, Cost Control and Team Leadership, Techno-commercial aspects & SCM. Green/Brown Field Projects, New Plant Setup, Overseas Technology Transfer. Proven track record of improving plant efficiency, reducing costs, and ensuring compliance with safety and quality standards.

Plant Head - M/s Ramesh Sun Wire Private Limited JV of Sunflag Iron & Steel Ltd. - Bhandara Nagpur

(2017-08)

Green Field Project & Plant Set up for Induction Harden & Temper wire for 2/4 Wheeler suspension spring wire. Oversaw the whole plant activities like Operation, Production, Production planning, RM Purchasing, SCM & Quality.

• Made Stabilizing unit, Tilting Mechanism & Packing Machine Locally in India, Saved INR 90 Cr
• Improve Chilling water capacity by increase water qty & Modifying heat exchange instead adding chiller
• To keep 100% up time of machine training given to production operator to do Preventive Maintenance
• Trained total 15 new operator in India within 3 months for Wire Drawing & IHTW lines
• After successive Initial Trail, within 6 months line running, achieved installed capacity 100%/month
• ITR - 3.5 Times
• On Time Projection Completion

Plant Manager: Domestic Division - M/s Gala Precision Engineering Pvt. Ltd - Wada, Thane

(2013-12 - 2017-08)

Overall responsible for Install, commission &

• Production the project of - Seat Recliner (Swaraj, Bharat Seat), Brush Spring (Delphi TVS), Damper &

• Pressure spring for Amalgam Repco, Mahindra Sona, Endurance &

• MK Lide.

Overall

Responsible for Plant Operation &

• Management activities. Responsible for achieving Monthly Manufacturing targets with optimal utilization of man, machine and material. Handling team of 80 colleagues in that 10 Staff member, 35 blue collar unionized & 35 Contract operator. Optimum use of resources to enhancement of Continual improvement, Production, Quality.

• Per Month Manufacturing value achieved INR 1.9 CR from 1.4 CR for Disc Spring
• 2014~15 year sales plan 18 Cr & Manufacturing Target 22 Cr. achieved
• 100% on time Customer Deliveries
• 100% Monthly Production/Manufacturing Value achievement
• OEE of Austempering improved from 65 to 74% in 6 month

Dy. Manager – Production - M/s Mubea Automotive (I) Pvt. Ltd & M/s Mubea Suspension (I) Ltd. - Chakan & Pirangut Pune

(2009-06 - 2013-12)

Overall responsible for setting, Instillation & Productionization of Dacromat Coating & Spring wire Induction Hardened & Tempered Project. Stabilization of process for new project & current processes like Dip spin Coating, Pre-treatment, Wire drawing + induction hardening + tempering Project. Maintain critical spares list of m/c's, Preventive maintenance & special care of critical m/cs. Keep machines up time 100%.

• For Spring band clamp- (Cost of Project 3 Cr) Coating Line Project Installed, Commissioned, Set, & Productionized. Installed capacity 700 kg/hr achieved within 4 months & enhance up to 900 kg/hr
• Suspension Spring Wire- (Cost of Project 25 Cr INR) Project Installed, Commissioned, Set & Productionized. Line's are- 1) Wire Drawing Line, 2) Induction Tempered Wire line installed capacity 700 Kg/hr achieved within 3 months from SOP
• Coating Line - Every month 100% Production Targets Achievement
• Raw material as well as Finish Goods Material inventory controlled from 10 mio clamps to 6 mio
• Lead Time of raw material order to receive reduced by developing weekly planning & ordering
• Productivity improvement from 74% to 85% (OEE) (Coating Line)
• Process stabilized for Thickness variation (Thickness variation reduced from 130 µm to 50 µm)
• Powder Consumption Reduced from 6.5 Kg/ton to 5.9 Kg/ton
• Powder Coating surface defects like waviness, uneven thickness reduced by 50%
• Induction Heat Treatment line installed for dia 9 to 14mm, Wire Dia range, enhanced up to 18 mm wire
• Major issue: Oven outer wall temp was more & Vibration of transport Wagon - resolved
• Major issue: Wire slippage while wire draw operation - Locking system Improved
• Major issue: Induction Line Set up change - New roller developed for easy change

Production Head - M/s Emitec Emission Control Technologies (I) Pvt. Ltd

(2006-08 - 2009-05)

Overall Responsible for Metallic Substrate/Catalytic Converter Operation Management. Efficient deployment of manpower in the shifts & Ensure the procedures & systems are being followed. Implementation of KANBAN system.

Training to manufacturing personnel – goal setting – team building – functional training – TPM – 5S. Adhering safety standards - related product safety, human safety and equipment safety etc. OHSAS. Small group activities - instrumental in promotion of small group activities like CFT for problem solving, CIP, Mistake proofing, safety, productivity improvement, TPM & Leading Quality circle team.

Handling team of 71 colleagues including 2 Sr. Engineer, 3 shift Engineer, 64 operators, & 1 Tooling Engineer.

• Reduced Overall Rejection from 2000 ppm to 500 ppm
• Improved Productivity from 125 to 144 substrate/man/day by reduction in setup & loss times
• Reduced setting time for new model from 180 Min to 75 Min & modification in new tooling
• 100% Production plan Targets Achieved every month by weekly planning

Sr. Engineer (Clutch Machining & Assembly Shop for 2 & 3 wheeler) - M/s Endurance Transmission Systems I. Pvt. Ltd. - Aurangabad

(2000-07 - 2006-07)

Overall Responsible for Daily Production of CNC m/c shop, Clutch Assembly & Friction lining. Responsible for New Clutch Production process development. Handling team of 91 colleagues including 4 shift Engineer, 87 operators. Heading projects to improve productivity by making single piece flow, SMED, Kaizen & TPM. Heading projects to reduce rejection by implementing POKAYOKE, Mistake Proofing & SPC Techniques.

• Improved Productivity from 45 to 67 clutch assly/man/day
• Reduced Overall Rejection from 5000 ppm to 120 ppm
• Cost saving Targets Achieved up Rs. 14 Lacs in year 2004
• Successfully developed Royal Enfield Clutch for 350 & 525 cc within given time
• CNC M/c production Increased from 37 to 45 no's/hr. by cell formation & reducing manpower
• OEE achieved 87% for CNC cell
• Lonely Handled the QS9000 Production Department Document & Internal Auditor for QS 9000

Engineer (Production) - M/s Gabriel India Ltd - Hosur, Tamilnadu

(1998-10 - 2000-07)

Responsible for Production of Shock absorber assembly line, Piston Rod, Welding & turning cell. Handling machine shop of centre less Grinding, resistance + CO2 welding & roller burnishing.

Trainee Engineer Maintenance & Machine Shop - M/s Patheja Forging Ltd - Satara & Chakan Plant

(1996-08 - 1998-09)

Responsible for Daily CNC shop Production & their tooling.