Resume Manufacturing Head, Operations Manager, Plastic Injection Molding in India Pune

KARKHANA.IO |Apr 2022-Present Head of Operations | Reporting to: Owner /Managing Director| Team Size: 16+ Role: Hired as a Technical Lead and mentor to check DFM of the product models received from the customer for this aggregate manufacturing startup. Implement company’s policies, regulations, and standard procedures for ISO 9001: 2015. Check and approve the process flow for the job. Discuss with the customer for improvement in Part/Project/Process. Guide and derive internal costing; help sales and sourcing to finalize the costing. Check and approve manufacturing process of job with supplier. Approve design of molds, press tools, jigs and fixtures. Make a quality approval plan for the product. • Streamlined the manufacturing department through proper work allocation, formulating and implementing SOP’s and introduction of process flow charts that resulted in timely delivery of part with appropriate quality. o Achieved 90% dispatch dates as per schedule. • Joined as Technical lead and was quickly elevated to Operations Head handling the manufacturing and quality departments. • Instrumental in getting ISO 9001: 2015 Certification (under process). RAUT INDUSTRIES |Apr 2017-Dec 2021 Operations Director/ Toolroom Consultant | Reporting to: Owner /Managing Director| Team Size: 150+ Role: Organized plant operations and implemented company’s policies, regulations, and standard procedures. Hired to manage P&L, streamline processes and establish safe equipment and workplace, execute plant policies and procedures. Led a team of 120 resources including Plant Head and other Department Heads within the mold shop/ toolroom to ensure all tooling are produced efficiently, on time and in line with quality standards for production. • Streamlined operations processes, increasing business turnover by 20% with same manufacturing setup. • Increased productivity by 35%, improved on-time delivery to 95% by reducing downtime failures and proper planning. • Restructured and reduced staffing overheads while improving customer satisfaction 20 percentage points. VARROC POLYMERS, India| Jul 2016-Mar 2017/ Mar 2005-Mar 2006 DGM/ Toolroom Head | Reporting to: General Manager | Team Size: 200+ Role: Brought on board to take charge of a crisis situation in the toolroom with over 30 people having resigned at one go. Led a team of 200 personnel in planning and operations of tool room for manufacturing 2-wheeler and 4-wheeler automotive parts. • Implemented policies and procedures, formulated operational strategies, built and mentored tool room employees and drove business results, achieved a FTR rate of 90% in seven months. • Recommended part quality improvement and cost reduction of mould manufacturing, analyzed and recommended purchase of tool room equipment. • Established and wrote tool room procedures to ensure consistent application of mold repair techniques. • Ensured quality equipment, materials and production standards, oversaw and maintained toolroom budgets and worked with engineers and purchasing team members to manufacture quality products that will meet customer’s expectations in the most cost-effective manner. • Closely coordinated with the Program Team for achieving the PPAP and production dates. T&G MOULD | Sep 2010-Jun 2016 Consultant- Business Head | Reporting to: General Manager Role: Recruited to develop and expand business footprints and procure mold manufacturing orders in India. Established healthy business relations with clients, involved with customer right from design stage to reduce total lead time in terms of communication and productionising the tool with desired quality. • Handled the techno-commercial operations and negotiated with clients for securing the order. Built and strengthened relationships with key accounts in India. (Siemens, TATA Autocomp, Whirlpool, Jai Hind Automation, Selec Electronics etc.) • Coordinated customer requirements with manufacturing units in Malaysia & China for quality tooling, mould build, commercials and timelines. TATA AUTOCOMP SYSTEMS, India| Aug 2007-Sep 2010 Deputy Manager Tool & Product Development | Reporting to: GM | Team Size: 3 Role: Hired for technology transfer of the best practices used in toolroom and to provide inputs on product design for easy manufacturing of tool and increasing the quality of the product & tool life. Analysed and reviewed the design of moulds with tool makers and provided inputs related to mould/product quality improvement. Attended the final mould approval trial at various toolmakers in India as well as abroad • Led development and manufacturing of innovative moulds for enhancement of product. Developed Hand brake Gap hider for Aria by insert molding- first time in India. • Instrumental in development and commissioning of projects like EPSILON, L38, MICROBUS, WINGER, X2 CROSSOVER, (Air Vents, Cup Holder, Console & its child parts), PRIMA truck (over 170 molds). • Achieved savings of over $2M by estimation of mould costs and evaluation of quotes received from vendors with emphasis on quality, economy and operational efficacy. • Conducted follow-up of moulds and got the moulds ready as per TACO-IPD standards. • Rectified design defects within minimum turnaround time with application of acquired troubleshooting skills. Implemented quality control measures to reduce rejections and minimize complaints. GODREJ & BOYCE MFG CO LTD, India| Mar 2006-Jul 2007 Deputy Manager Tooling | Reporting to: General Manager Toolroom Role: Responsible for planning and manufacturing in Toolroom, inspection of tools, components, gauges, jigs and fixtures. Conducted DFM analysis of part for manufacturing with the designer. Interacted with customer for the requirements of quality. • Saved over INR 5 lacs for the organization by implementing 5S. • Projects completed; steering column, floor console, Ac duct, hand brake console, et. for TATA and Renault • Awarded special performance bonus for achieving Tool production over and above the scheduled target. PREVIOUS ASSIGNMENTS HOD-Toolroom |TRI PLUS INDUSTRIES, Malaysia/ Slovakia Oct 2002-Dec 2004 Controlled assembly and proving of new mold till production, modification of molds, design changes and improvements in molds. Manufactured Molds for Parts like Bezel, remote control, front panel and child parts, mechanism parts for customers - Panasonic, JVC, Sony, Bosch, etc. • Served as HOD tool room in Slovakia where critical molds of Panasonic, JVC were maintained and modified. Assembly Head |VIDEOCON INTERNATIONAL, India Oct 1999-Sep 2002 Led the Assembly section directing a team of 70 personnel. Responsible for planning and execution of manufacturing till the product is launched. Completed projects of television, blenders, washing machine parts and coolers Officer-Toolroom |VIP INDUSTRIES, India Oct 1996-Oct 1999 Initially responsible for the planning machining strategy and timely delivery of mold parts. Assembly and proving of molds. Trainee Officer |LEGRAND (formerly MDS SWITCHGEARS), India Oct 1995-Aug 1996 Handled the maintenance of press tools and assembly fixtures.

• Advanced Diploma in Business Management | Wellingkar Institute, Mumbai, India|2013 • 4 years Diploma in Tools & Dies | NTTF Tellichery, Kerala, India|1995 • Trainings: 5S training, Kaizen, TOC, NLP, Graphology, Watch Analysis & Therapy

Strategic Visioning & Planning ~P&L Responsibility ~Revenue Growth~ New Business Development ~ Tool Room Management ~ Lean Manufacturing ~ Techno Commercial Operations ~ Mold Cost Optimization ~ Team Development & Training

-

Skilled Operations Leader offering over 25 years’ career success in Plant Operations, Toolroom Operations, Program Management and International Business Development with top grade industrial establishments in India and abroad. • Started as toolmaker and rapidly progressed to positions of increasing responsibility in Tool Manufacturing as Head of Toolroom, Deputy Manager Tool & Product Development, Head Business Development, Operations Head and currently providing expertise in streamlining operation processes for an aggregate manufacturing startup. • Ability to leverage techno-commercial support to Indian customers during mould manufacturing and post SOP, leading to business expansion of representative toolrooms. • Broad experience in planning and execution of mould manufacturing to ensure target adhered for tool development. • Credited with engineering innovations and in–house developments leading to substantial cost savings to the company. • Expertise in DFM and manufacturing methodologies. • Effective communication, interpersonal and team management skills. Meticulous, practical and structured approach with planning & implementation skills.