SANDEEP SAINI _ (Manager / Deputy Manager _ Production)
DEPARTMENT’S EXPOSURE: 1.Production 2. Maintenance 3. Process Engineering 4. New product Development 5. PPC 6. Quality 7. New Line Set Up.
MANUFACTURING EXPOSURE: 1. Automobile (Top Tier 1) 2. Driveshaft Assembly 3. Seating Assembly
4. Press Shop 5. Grinding 6. Packaging
PRODUCT EXPOSURE: Seating System & Door Trim Lng., Constant Velocity Joint Driveshaft (Axle), Chain Tensioner, Ceramic Wall & Floor Tiles
CUSTOMER EXPOSURE: Automobile (4 Wheeler - MARUTI, GM, Toyota, Nissan, HONDA)
CTC : 10.60 Lacs/Annum
Experience: 16 years, snnysaini@yahoo.com, snnysaini@gmail.com
CELL No.: 7728891935, Passport No: , Address: H.No.-71, Old Housing Board Colony, Sector-1, Distt. Rewari, Haryana
OBJECTIVE:
Seeking assignments to Manager - Operations with key focus on Process Enhancements / Operations’ Management / Business Development with a growth oriented organization.
PROFESSIONAL SYNOPSIS:
§ 16 years of rich experience in Operation’s Management, Process Enhancements, Quality / Cost Control, Project Management and Man Management.
§ Presently working with TS Tech sun Rajasthan as Dy. Manager, heading Seating & Door Lining Assembly with Rs.319 Cr. turnover and 470 people.
ACADEMIC QUALIFICATIONS:
§ Diploma in Production Engineering & Industrial Management from Govt. Polytechnic Sonipat in year 2000.
§ Master’s Degree in Business Administration from Guru Jhambeshwar University Hisar in 2005.
ORGANIZATIONAL EXPOSURE:
SEP’14 TO TILL – TS TECH SUN RAJASTHAN INDIA PVT. LTD. NEEMRANA:
Since Sep’14 with TS TECH SUN RAJASTHAN (Japanese MNC) as a Deputy Manager.
TSSR is a Japan based MNC having joint venture of TS TECH (97%) with TSSI (1.9%) & SUN VACCUM (1.1%) and leader in the business of providing complete Seating & Door Trim solution for passenger’s cars in India for Honda Cars and Honda two vehiclers.
Manufacturing Plan:
§ Coordinate with the Planning team to create the monthly Production Plan (on the basis of current Capacity) maximizing utilization of each line, maintaining the product mix as per prioritization of customers.
§ If required, re-plan the production schedules as per prioritization of customer orders & pending orders and ensure communication to line in charges.
§ In case of any Material issue (shortage/lot rejection/containment) coordinate with the procurement team to ensure timely availability of quality raw materials considering Production Plan and Customer Dispatch.
§ Coordinate with the Inventory Management team for preventive maintenance and to account for shut down schedules by incorporating the same in the production plan.
Production Management:
1. Calculating Resource Requirement for future months and quarter’s like Man Hours, Man Powers, Machine Hours, Tools, Materials.
2. Working towards Man Power calculation and controlling their Numbers with man Hours and over time.
3. Calculating Direct & In Direct Worker’s Efficiency by studying and Improving their working methods and skill level.
4. Capacity Calculation and enhancement for PLANT, LINE, MACHINE, MAN POWER, PROCESS.
5. Working Towards Identification of Bottlenecks in Manpower, Machine, Process, (any restriction in target achievement and Improvement) with an action Plan for Debottlenecking them and improving their efficiency and performance.
6. TAKT Time Calculation for Predetermining Future Requirements & doing Time study and Work Measurement for Setting the Targets of Man Power, Machine and Process.
7. Finalizing and Preparing Cycle time Study sheet with process flow of Cyclic Steps for defining Production targets and manpower.
8. Doing Line Balancing for all Processes and Machines with a scope of Productivity Improvement and balancing worker’s Load and reducing / eliminating MUDA, MURA, and MURI from their Work.
9. Working towards Productivity Improvement by improving their Per Hour Performance.
10. Fixing and finalizing Layout for Standard parts location for Controlling Child Part Inventory and WIP on Shop Floor.
11. Improving and controlling Machine’s Health by confirming Daily Machine Control Check Points.
12. Implementing 5S on shop floor and educating worker’s for the same. Designing and Implementing a system for sustaining 5S.
13. Design, Development & Calculation of Man Power, Tools, Equipment, Machine, Bins, Trolleys, Racks, Working Tables for manufacturing set ups .
14. Designing and Developing Andon System for fast response handling and fast information circulating during any Abnormal Situation.
15. Working for KAIZEN Team Design And Suggestion Scheme implementation for motivating workers and sustaining them for long run.
16. Designing POKA YOKE in system so that minimum errors will generate and anybody can do the operation without fail.
17. Working on Changeover Reduction and designing the flow, training to people, availability of all resources (material, man power ) so that minimum time will consume in any Changeover.
18. Working on Ergonomics Improvement so that the performance of worker increase and the long run efficiency sustain in Body, Reduction of fatigue by improvement in Environmental Conditions like Moisture, Air, Ventilation, Sun light, Weight of Tools, etc.
19. Daily Data Analysis of Department Targets with reports and Records like Individual Line OEE, Rework , Rejection, Man Power Availability per shift as Planned, Over Time, Major Breakdowns with Trouble shooting ( MTBF and MTTR Line wise).
20. Developing Different CFT’S for Plant Improvement Activities and mentoring them for achieving their Projects Like, COST SAVING, QUALITY IMPROVEMENT, and other projects (project based on SMART and 5W+ 2H methodology.).
21. Working with HR for designing, finalizing, monitoring, controlling and improving KPI’S of SHOP FLOOR workers & Staff Members.
22. Designing NEW Man Power Training and Development System on Shop Floor for improving effectiveness of “Man Power Life Cycle” methodology and Induction Plan.
23. Improving Worker’s Skills on different stations/ processes/ machine’s by designing their JOB ROTATION PLAN. This will help in managing Man Power Absenteeism and Attrition Rate Problem (Especially in Festival Season).
24. Working towards standardization of work & processes to improve quality of work like per hour output, data collection, standard tools.
Maintenance Management:
§ Working with Maintenance team for the Spares Management to reduce the MTTR and MTBF for the Assembly Line machines.
§ Working with Maintenance team and HR team for ensuring Safety in Plant, Machine Safety, Man Power Safety & Product Safety.
Quality Management:
§ Ensure the product is delivered within First Time Right (FTR) principles.
§ Ensuring the Machine start with Set up Change Approval and Parameter check to produce a single part with quality control whether it is in Morning (Start of Production) or during Mid-Production Changeover.
§ Making working instructions and all line documents (OSG, Process Parameter Sheet, Validation Sheet, Skill Matrix Chart, Skill Rotation Plan, Operator Training Sheet, Defect Record Sheet, PPE Sheets, Visual Docs, (OEE, FTQ, SCRAP%, PPM%, ETC.).
Project and Process Engineering
§ Review plans and discuss with P.E dept. and support staff to develop new products and processes before launching to production.
§ Ensuring that before handed over to production new line should achieve the defined target with minimum 1000 continues pcs. With achievement of OEE/ FTQ /MTBF/MTTR targets with spare parts and all machines documents availability i.e Circuit Diagram, PLC Program, Specification of Spare Parts, Vendors and Drawings, etc.
SYSTEMS ADHERENCE
§ Responsible for the Production System / Process across zones to ensure both internal & external audit compliance including TS16949/2009.
§ Responsible for ensuring the Line operates within site Health & Safety policies & procedures.
ACHIEVEMENTS:
Category / Points / Year 2014-2015 / Year 2015-2016 / Idea of SavingCost Reduction / To reduce Consumable Cost / 19% / 23% / Dual Sourcing & Optimum Utilization
To reduce Overtime Cost
(Front & Rear Seat Assy) / 8,65,728 INR / 5,24,553 INR / Cycle Time Reduction (70Sec.-60Sec.)
To reduce Overtime Cost
(Door n Sw. Pnl. Assy) / 6,69,240 INR / 4,51,213 INR / Cycle Time Reduction (50Sec.-40Sec.)
Quality / Customer Complaint / 28 / 4 / Strengthen In process Quality as well as Supplier Quality
Supplier Rank @ HCIL / 197 / 4 / Skill Level Up Through Quality Education
GQI Rating / 84.34 / 3.3 / Implement C/M from Overseas Input
Rejection PPM / 1206 / 7 / Day to Day Rejection Data Analysis, Fix Countermeasure
Productivity / Seat Assy. / 13.8 Carset/ Man/day / 18.7 Carset/ Man/day / Line Balancing through Time Study
Door Assy. / 11.9 Carset/ Man/day / 14 Carset/ Man/day / Line Balancing through Time Study
System / ISO/TS16949:2009 / -- / Certified in 2015 / Team Work & Coordination among all departments
TS Japan QAV & QCD Audit / 53.8% / 84.8%
2.2/5 / Working towards Quality Management Systems
FEB’07 TO AUG’2014 – NTN NEI MANUFACTURING INDIA PVT. LTD. BAWAL:
M/S NTN NEI Manufacturing India Pvt. Ltd. (An ISO/TS 16949:2009, ISO 14001:2004, OHSAS 18001:2007 certified) is a group company of NTN CORPORATION (JAPAN) in collaboration with M/s NEI Ltd. (NATIONAL ENGINEERING INDUSTRIES LTD. JAIPUR) leader in Bearing manufacturing engaged in manufacturing of Constant Velocity Joint Driveshaft (Front Wheel Drive Axles) for all leading automobile companies.
1. Monitoring Assembly Line and achieving daily production targets.
2. Manpower Planning and Multi Skilling of Associates.
3. Handling the team of 140 associates, provide them technical support & maintain up-to-date Training Matrix.
4. Conduct the Time Study for all operations performed on assembly Line & to standardize the cycle time. Continuous working towards Quality and Productivity improvement through Kaizen activities, 5’s implementation, Training, Safety and Audits.
5. Improvement and updating layout of existing line and installation of new assembly machines.
6. Capacity Planning as per production plan for the year.
7. Provide location for all material (Bought Out Parts) used on assembly line.
8. Working on ERP (NAVISION) system, OEE calculation and Line Balancing (Balancing of Activities).
9. Management & Procurement of Assembly Line Set up Change Tooling.
10. Maintaining Tooling History & monitoring Tooling Life.
11. Set up Change Tooling trial for new models and involvement in development activities.
12. Properly recording and analysis the production and rejection data per shift.
13. To prepare the Plan Vs Actual Production, Rework & Rejection data, Consumables & Man power utilization data on monthly basis.
14. Implementation of Poka-Yoke on machine for critical operation.
15. Handling of ISO/TS 16949 documentation, maintaining of all documentation and reporting.
16. To prepare Standard Operating Procedures, Work Instructions, Training Modules on product and process.
17. To ensure export packing of Spare Child parts & Assembled Driveshaft for General Motors as per QSB standard.
18. To ensure the packing and dispatch of service parts for MSIL, TKM & GM as per customer standards.
ACHIEVEMENTS:
Category / Points / Year / Result & Idea Behind ResultGreen Field Project / Set up of Assy Line for MSIL
(NNMI Bawal) / 2007 / Start up with initial level and achieved the highest production 768 pcs. per shift & 2064 pcs. per day by implementing TPS.
Set up of Assy Line for GM (NNMI Bawal) / 2010 / Achieved the highest production target from 250 pcs. to 768 pcs. per shift by implementing TPS.
Functional Trail of Assy Line (Chennai Plant) / 2012 / Functional Trial of all Assembly Line machines successfully
Quality / Represented 2nd Global Quality Circle Competition held at Japan / 2012 / Represented NNMI in Global Quality Circle Competition and got 3rd Position
Productivity / OEE increased 57% to 78% / 2011 / To find the losses & take countermeasure on them
Enhance Productivity by 23% / 2012 / By Elimination of Wastes
System / ISO/TS16949:2009 / Certified in 2010 / Through implementation QMS
ISO14001:2004 (EMS) / Certified in 2010 / Team Work & Coordination among all departments
OHSAS18001:2007 / Certified in 2010 / Working towards Quality Management Systems
OCT 2000 TO JAN’2007 – SPL LTD. BAHADURGARH:
SPL Ltd. is a second largest manufacturer of quality wall and floor tiles in the country with a turnover of Rs. 300 corers. SPL Ltd. is the first tile company in India to be honored both prestigious ISO 9002 and ISO 14001 certification for his manufacturing set up.
§ To look after the production in shift.
§ To achieve daily production target with zero defect quality.
§ Minimize the rejection and increase the production.
§ To improve the quality by removing thickness variation, penetration, side cutting problems.
§ To handle manpower i.e. fitter, operator and helpers etc.
§ To work with sensor based PLC controlled equipment’s.
§ Analysis ability of day to day problems and implementing effective solutions.
TRAININGS ATTENDED:
§ General awareness on ISO/TS 16949:2009, ISO 14001:2004 & ISO 18001:2007
§ Problem Solving Techniques
§ Potential Failure Mode & Effects Analysis (PFMEA)
§ Statistical Process Control
§ 5’S and Kaizen
§ Certified Internal Auditor For ISO/TS-16949:2009
OVERSEAS EXPOSURE:
1.NTN CORP. JAPAN:
§ Participated in 2nd Global NTN QCC Convention held at Kuwana City Japan and got 3rd Position in 2012.
§ 2 Week Technical Visit of NTN Iwata Works, NTN Fukuroi Corp., NTN Mie Corp. & NTN Kuwana Works.
2. GENERAL MOTORS UZBEKISTAN:
§ 1 week visit at General Motors Uzbekistan for the supplier meeting with customer - regarding handling of product, packing improvement and quality issue closing.
SANDEEP SAINI