CORE COMPETENCIES

 

Manufacturing Operations

Managing the overall Modern Manufacturing operations for more than 19+ years.
Designing & Manufacturing of jigs, fixtures & cutting tools, including design and reviews.
Responsible for verifying inspection, preparing inspection schedules and dispatch of Component and Projects materials.
Meeting the Development targets within time and Budget parameters.
Optimizing Man & Machine utilization to achieve pre-set production targets.
Plan, Manufacture, as per schedule, Initiate Tool Trials and handover the tool after successful Trials
Designing, implementing and monitoring effective procurement schedules along with finalizing the specifications of the spare parts and establishing the quality & quantity limits.
Initiate CAPA, Kaizan, Lean, 5S for efficiency and perform RCA with Ishikawa-Fishbone Diagram
Programming for CNC Milling 3-5 axis, CNC lathe 3& 4 axis, CNC Wire cut up to UV Complex axis, CNC Water jet, CNC EDM.
Headed Modern Manufacturing Department with CNC Mill, CNC Lathe, CNC Wirecut, CNC EDM Spark, CNC Waterjet, CNC Plasma and Conventional machines.

Multi-Site Handling as Business Head

While working in India handled Local Team, Malaysia, Netherlands, Belgium, Turkey for Aerospace, Semiconductor, and Medical Devices from Marketing, Design, Manufacturing, Quality Control and delivery of Components and Assembly Packages. From India handled Mexico, and Various site in USA including Tucson, Arizona, Westminster, Vista and Compton of California, Miami and Nogales Mexico plant for Design to manufacturing of Aerospace, Defense and Space Components and assemblies. While working in Kuwait handled both Kuwait and Jeddah factory for Product development and production. In Dubai was handling both Dubai Wire and Global Fasteners New Tool Design, Manufacturing, Production support and maintenance of plant. Prepare business plans, Budget, ROI Plan, execution, Infra and Machine equipment planning, to Board reporting for multiple sites.

Design Engineering and Product Development

Developing new products, subsystems, systems, Machines from concept design, validation, realization, trials & testing Proto-typing, prove-out to production along with Technology transfer and training by providing sound technical inputs and engineering support to the team from conception to completion stage of the product.
Creating Assembly Design in 3D, detailing design, preparation of BOM & prototype development.
Responsible for analysing and producing the technical requirements and specifications.
Managing the overall operations for the improvement in the existing products based on market trends and requirements.
Recommending design modifications based on DFR, DFM requirements and actively conduct reviews for both.
Monitoring product quality & impact of design modifications on product features after DFR and DFM incorporation.
Writing technical documentation, describing the specifications/usage of products in multiple languages with team.

Quality Assurance

Ensuring compliance of various quality measures.
Implementing AS9100 Rev C and ISO 9000 standards and maintaining the relevant documents.
Designed Process, Methodology, Standards, Risk assessment, fishbone requirement part of QMS
Practicing quality standards with key emphasis on improving quality and Processing from Client Inquiry, Review, estimation, Proposal preparation, Client interaction, Kick-off, Project plan, Monitoring, Execution, completion, Delivery, project closure, summary and feedback from client.

Product Development

Managing the overall operations for the improvement in the existing products based on market trends and requirements.

Co-ordinating the entire product development including requirement analysis, finalizing specifications, designing, prototype development and testing activities.

Providing sound technical inputs and engineering support to the team from conception to completion stage of the product.

 

Aerospace, Space, Defense, UAV Component Machining, Special process and Assembly

Designed aerospace parts, developed tools like vacuum fixture, Press Tool & Dies and Moulds. Worked closely with Client in France, Germany, The Netherlands and defined process of Manufacturing for both Commercial aircraft components and Fighter jet components. Worked on wing and windscreen components and assembly.

NC code generation utilizing Mastercam-X3 for 5-Axis Machines with fixtures for unmanned vehicle parts.

Reviewing Process sheets, guiding team in designing Jig, Fixtures, Press tool drawing and Forming Dies.

Involved in Execution of CAM and NC programming in US facilities both onsite as well as offshore support from Indian offices. Have hands on in executing projects of Missile, Fighter planes, Commercial jets, Business jets components including Engine parts, skins, Primary and secondary structures. Have involved in getting initialization to client approval for Anodizing (SAA, CAA, Thin SAA, and Hard Anodizing) and Conversion coating for two major Tier1/OEM.

Team Building, Man Management and Leadership

Setting Strategy and have clear vision for each members, their role and setting levels in each hierarchy and getting not only the work, but show a clear growth path for each contributor make every member of the team be motivated to perform. Build Team for New process with process and ramped the team to triple digits in the filed of Design, Manufacturing, CAD, CAM, Technical publication and Composite Mould design and Methodology team, Assessing the training needs of the various employees in co-ordination with the various department heads in the respective departments. Coaching employees & counselling, appraising and reviewing performance, ensuring optimum performance. Handling work force team of 7 to 52 in tooling and development assignments.

 

Blow Moulids Purview

100ml_savlon Bottle, Half litre and one litre KINLEY BOTTLE, Muscle bottle Half litre, Spinz 20, 50, 100, 200, 400 grams shampoo bottle, Side ribbed bottle 100ml, 200 ml and 500 ml for Kenya, Apple shaped bottle, 1250 grams tea jar, Half litre kinley bottle & One litre kinley bottle, Half litre coke bottle, One and half litre Fanta bottle.

 

Forging and Casting Purview

Developed Sand casting, Gravity casting, Pressure die casting components and moulds. Have worked in reducing total product management with CAD, CAM and CNC machine utilization to reduce the design and development time since 1999. Developed pattern to Tier 1 of OEM’s to have smooth operation in both Design and CNC/CAM programming.

 

Installation, Commissioning and Troubleshooting

Installation and commissioning of CNC Milling, Lathe, Wirecut, Spark Erosion EDM in UAE in 2006 Insallation and commissioning of CNC Milling and CNC wirecut machine In Cirteq Engineering in 2007.

Installation and commissioning of CNC Milling, Lathe, CNC Waterjet, CNC Plasma in Ray precision Engineering in 2011. I have been the Trouble shooter for the Machines in Kuwait, Dubai-UAE, Cirteq-Chennai and Ray precision Engineering Muscat Oman.

 

Technology Transfer

I went to Wafio's Germany to acquire the nail manufacturing technology and maintenance of nail machines and transformed the same to Dubaiwire through Visual (Video) Training program.

I was the only person to communicate the technology of UK to Citeq India and developed the process and tools as followed in UK. Also worked closely in developing modern machining technology from France, Belgium, The Netherlands, UK and Malaysia.

Not only transferred the technology of manufacturing of Aerospace from US to India but also implemented some of the Indian better methods to US and got accredited for the same from VP of both Vista and Tucson.

Act as main pillar for transferring Missile, Space and defence technology to Godrej and also continuously involved in trouble shooting of manufacturing feasibility with DRDO Hyderabad and VSSC.

Composites Domain

I did developed Composites Moulds, layup Process, Sequence design, A CUT and B CUT for Nomex Panel, Honeycomb Aluminium Panel and developed Trimming of Complex shaped Composite panels. Worked closely with C2 composite to transfer the technology from UK to US/Mexico and Support from India. Developed series of moulds for different Interior and cabinet composite parts from concept of part to end process and Methodology support. Worked on Prestigious project for wind turbine blade and tail wing for the Windmill that was, designed, manufactured through vendor and installed at 3000 Msi at banihal top in J & K.

 

Thermoforming

Develop Open cell eps foam extrusion for EPS absorbent trays where the middle layer to absorb the liquid from Tray and other products by enhancing the line of Foam production from granules. Worked on latest CAD CAM CNC technology for Tool Design, Manufacturing including Precision metal trim dies for EPS foam (Irwin Research Machines), EPS foam extrusion, re-palletising of eps foam, EPS cup molding and tooling for EPS cup tooling, Plant layout and erection with all utilities. Re-designed products and achieved reduction of stack height and reduced great cost on Transportation. Design and Develop Thermoform cases for weapons.

 

Supply Chain Management

Developed a database of suppliers in aerospace in India for manufacturing in 2008 for BE aerospace.

Process ownership for supplier selection, Audit, capability study, Supplier Registration till Project delivery.

Supplier review, frequent meeting, Design Change and other activities related to Design and Methodology. Work closely with suppliers of other industries enhancing precision and process oriented approach and qualify them for Aerospace manufacturing in Mumbai region for Godrej aerospace. Guide and support supplier on technology and process for PMI and enabled almost 40% of components manufacturing from supply chain.

 

Performance Management, Admin and Purchase management, Installation Commissioning of machines and equipment’s

Installation of Power backup and Server and workstation systems for Engineering division, Unload, Install and initiate greenfield project for Thermoform Machines, CNC Machines including Milling, Turning, TurnMill, WireEDM, Spark Erosion machines, Installation of Furnace, Boilers, Presses, Robots, Expanders, Customised Machines. Take care of OEE, CAPA, RCA, Fishbone and other Lean Process. Purchase of Machine, Material, Hardware, software and other requirement for operations and Budgeted expansion from Business plans.

 

Client Management

Developed strong professional relationship with Clients of Aerospace and Defense OEM in USA, Turkey, France, The Netherlands, Germany, Medical devices and Semi-conductor client in Germany and The Netherlands, Frequently travel to Client site and work closely in achieving the goals and targets. Prepare solution and present to client rather than raising queries. Prepare and present client specific presentation for acquisition of New client or projects with existing clients.

 

ISO9001, AS9100 ISO13485, ISO14001 & Nadcap certification and Customer specific approvals.

Right from 1996 started working on ISO 9001 for Indo German Tool room, and from 2008 involved on AS9100 organization and have successfully faced and cleared 11 audits till now. Have also worked for Nadcap audit for PMI Global organization, right from machine setup to certificate, trials and clearances I have lead the entire team and got success for both AS9100 and Nadcap for both manufacturing and Special process and customer approvals for different process.