Sudeep Tripathi
Production Manager
Aurangabad,MH
Summary
Dynamic and results-oriented professional with over 15 years of experience in manufacturing, dedicated to driving success within a reputable organization while achieving personal and career aspirations. Committed to professional excellence, continuous improvement, and adding value through innovative thinking and effective team collaboration. Eager to leverage expertise to foster growth in challenging environments, ensuring a positive impact on personal development and organizational objectives. Passionate about embracing new challenges and adapting to evolving industry demands.
Overview
15
15
years of professional experience
2
2
Certifications
2
2
Languages
Work History
Head of Production (Bogies & Components)
Siemens Ltd
06.2022 - Current
- Operation mgmt. & Industrialization
- Role of Production Team Leader (Head of Production): - Siemens Ltd.
- Responsible for producing components, products and systems, whilst meeting delivery deadlines, quality standards and cost targets. Achievement of maximum efficiency and productivity through continuous improvement of processes, technologies and skills. Optimal product life cycle support through close cooperation and alignment with business partners (e.g. project management, purchasing and logistics, Production planning, engineering, quality management & top brass mgmt.)
- Current Job description (Responsibility): - Siemens Ltd.
- Operational responsibility for planning (capacity, deadlines, staff, areas/space, inventories, overhead costs and investments), execution, monitoring and continuous improvement of a production area whilst complying with objectives for customer demand/deadlines, quality and costs, and EHS.
- Disciplinary responsibility for staff: Selection, recruitment, leadership, classification, promotion, motivation, dismissal of employees.
- Achieve optimal earnings contributions through continuously increasing productivity, e.g. through continuous optimization of processes and technologies. Consistent advancement of Lean Production activities as part of the Siemens production system.
- Ensuring that the production and delivery of components / products / assets / systems to the client(s) is on schedule and in accordance with quality and quantity at competitive costs and compliant with the market requirements.
- Further development and innovation in the area of responsibility, in order to be able to meet existing and future client needs even better.
- Collaboration with development, sales / project management, purchasing and other business partners to work out and implement effective and innovative production strategies and concepts.
- Trust-based collaboration with the works council in coordination with the responsible site management, as well as collaboration with external partners (e.g. suppliers in coordination with the relevant purchasing department)
- Ensuring compliance with existing laws and directives (e.g. occupational health and safety, environmental protection ISO 14001 & 45001, Siemens directives) in your own area responsibility.
- Communication and reporting within the plant to mgmt.
- Qualification of engineers & supervisor to become expertise for meticulous load testing of 3 & 2 axles heavy bogies i.e. (EF09K Locomotives, Tram & Metro platform bogies)
- Evaluation of skill matrix of staff to plan their forthcoming training to meet day by day upcoming challenges which are converted into opportunities.
- Further development and innovation of the production unit, in order to be able to meet existing and future client needs even better.
- Led production planning and execution for bogies and components, ensuring on-time delivery and quality standards.
- Streamlined manufacturing processes by implementing lean principles, resulting in improved efficiency and reduced waste.
- Collaborated with cross-functional teams to optimize supply chain operations, enhancing material flow and resource allocation.
- Mentored and developed production staff, fostering skill enhancement and promoting a culture of continuous improvement.
- Led production teams in optimizing processes for bogies and components, significantly enhancing operational efficiency and throughput.
- Implemented advanced quality assurance protocols, ensuring compliance with industry standards and reducing defect rates.
- Fostered cross-functional collaboration to streamline project timelines, improving stakeholder communication and project delivery rates.
- Spearheaded the adoption of lean manufacturing principles, resulting in waste reduction and improved resource allocation.
- Developed and executed strategic production plans, aligning organizational goals with manufacturing capabilities for optimal performance.
- Mentored and trained production staff on best practices, enhancing team skills and overall workplace productivity.
- Conducted regular performance reviews and process audits to identify areas for improvement and drive continuous operational enhancements.
- Championed safety initiatives within the production environment, contributing to a culture of safety and compliance across teams.
- Mentored junior team members, fostering professional growth and contributing to a positive work environment.
- Reduced manufacturing downtime through proactive equipment maintenance and employee training.
- Collaborated with cross-functional teams to improve product design, ensuring manufacturability without sacrificing quality.
- Developed a comprehensive production schedule that aligned with company objectives and deadlines.
- Enhanced quality control protocols, resulting in fewer defects and improved customer satisfaction levels.
- Established clear performance expectations for staff members, holding them accountable for meeting targets while providing necessary support for success.
- Optimized resource allocation by developing efficient staffing plans that maximized utilization rates while minimizing overtime costs.
- Conducted regular performance reviews for employees under my supervision; these evaluations led directly towards improvements in individual performance metrics.
- Increased production efficiency by streamlining processes and implementing innovative strategies.
- Championed a culture of continuous improvement, encouraging team members to actively engage in problem-solving and share ideas for enhancing operational efficiency.
- Spearheaded continuous improvement initiatives that resulted in measurable enhancements to productivity and overall performance metrics.
- Implemented cost-saving measures that led to significant reductions in operational expenses without affecting product quality or delivery timelines.
- Analyzed production data, identifying trends and areas for improvement which led to more informed decision-making processes.
- Successfully managed multiple projects simultaneously while maintaining stringent adherence to quality standards and deadlines requirements.
- Led the implementation of new technology to optimize workflows, resulting in reduced lead times and increased output.
- Facilitated change management processes during major organizational shifts which helped maintain employee morale and minimize disruptions to productivity levels.
- Developed strong working relationships with key stakeholders, enabling better communication between departments and improved collaboration efforts.
- Maintained high safety standards, leading to a reduction in workplace injuries and lost time incidents.
- Resolved issues quickly to maintain productivity goals.
- Monitored team budgets to keep projects on task and avoid waste.
- Created streamlined production schedules and collaborated with production employees to communicate objectives and goals.
- Estimated labor requirements to support anticipated workload.
- Standardized production procedures, job roles, and quality assurance guidelines.
- Managed continuous improvement initiatives to drive gains in quality, flow, and output.
- Managed internal operational standards and productivity targets.
- Determined suitable crew requirements, scheduled employees, and worked with human resources to meet changing production schedules.
- Reviewed work for quality and compliance with company standards and design specifications.
- Sourced materials to keep up with production goals and meet customer demands.
- Partnered with leadership on recruiting, hiring and coaching production personnel.
- Reviewed maintenance and repair problems to determine appropriate action for resolution.
- Studied department operations to assist with development of new or improved methods of tooling and production processes.
- Delivered direct feedback to senior management regarding project visibility and status.
- Monitored daily and weekly key performance indicators to maintain on-track status.
- Cultivated professional working relationships with peers and supervisors.
- Interpreted work order information and specifications to plan, schedule and complete jobs precisely.
- Enhanced processes by pinpointing bottlenecks and working with supervisor to resolve.
- Led improvement initiatives to advance operational efficiencies and increase revenue.
- Collaborated with internal teams to streamline operations across materials handling, production, and shipping.
- Created and implemented strategies for improving operational efficiency and accuracy.
- Troubleshot equipment to reduce service calls and downtime.
- Located and resolved problems with team production and performance to maintain consistent quality levels.
- Kept accurate and detailed records of personnel progress and productivity.
- Implemented policies and standard operating procedures for continuous improvement.
- Collaborated with other leaders and executives to direct workflow and support operations.
- Managed staff hiring, training and supervision.
- Planned, organized and monitored resources to deliver efficient use of labor, equipment and materials.
- Supervised ongoing daily production phases.
- Established operational objectives and work plans and delegated assignments to subordinate managers.
- Increased customer satisfaction and grew business by maintaining close relationships with customers.
EPU - Manager (Wheelset & Bogie Assy.)
Alstom Transport India Ltd.
02.2021 - 06.2022
- Operation & Process improvement
- Past Job description (Responsibility): - Alstom / Bombardier Transportation
- Operation handling – Final assy. Bogies i.e. (Wheelset and Bogie assy.), Fabrication critical rework.
- Follow correct GD &T, Drawing and Standard adherence.
- Maintain all Production KPI’S accord. to standards.
- Solving Internal / External Customer problems.
- Using SAP transaction to handle operation.
- Budget calculation – Head count, EAC hrs., ODC cost & Cost center input etc.
- Raise e-buy of all NPR consumables related to the operations.
- Continuous improvements (5S & Kaizens, Quality near miss & safety near miss)
- Special process qualification i.e. (Pressing and Torquing)
- New production development trials and implementation.
- Product approval, Control of parts manufacturing & documentation during assy.
- Coordinate with Incoming & supplier quality to implement correct parts as per requirement.
- Standardize production & new processes to improve productivity.
- Using macro programming in all machines to have user approachable & mistaken proof variables part manufacturing.
- Follow the MRF process using NCR on supplier and inhouse.
- Managing the measuring instrument – micrometer, linear scale, vernier and bore gauge, dial gauge, temp. sensor, roughness tester & electrical resistance tester etc.
- Handle - Hydraulic machine- Vertical & Horizontal, Resistance tester equipment & dynamic bogie testing machine.
- Manage the Machine Programming in MAE Wheel press machine & implementation of component setting on PLC based machine (Siemens).
- Presenting operation progress report quarterly, half yearly and yearly basis.
- Responsibility to manage skill matrix and multiskilling of engineers & Technicians in Final assy.
- Manage the rework activity in Machining, Assy, and fabrication production.
- Handle layout of shops to reduce waste and increase the production capacity by introducing new tools and fixtures to enhance machine capacity.
- Revalidation of tools, jig fixture & other subassy. on time to sustain production capacity with the right quality.
- Handle TS 22163 internal audit.
- CASRA audit (hrs. booking).
- CAPA, FMEA & PPS database.
- VSM, Line Balancing & time study to establish optimum cycle time of product manufacturing.
- Assemble Bogies (Mechanical drives) using hand tools and do validation and testing in serial production correctly as per standards & drawings requirement.
- TAKT & TPT improvements.
- PDCA database (PQRC) implementation & BTRT Reporting.
- Managing the production & raw material planning and control.
- Customer support after handover final product.
- Initiate lean manufacturing environment for more efficient and safer work practices.
- Completed project: - QNGR EMU, DMRC metro, Riyadh metro & Victoria.
- Latest project: - DMRC metro, Agra Kanpur metro, RRTS metro, Adelaide metro, Victoria metro.
- Led the optimization of wheelset and bogie assembly processes, resulting in improved efficiency and reduced cycle times.
- Managed cross-functional teams to implement safety protocols, ensuring compliance and enhancing workplace safety standards.
- Developed and streamlined quality control measures for assembly operations, significantly reducing defect rates and enhancing product reliability.
- Initiated training programs for staff on assembly best practices, fostering skills development and improving overall team performance.
- Conducted regular audits of assembly workflows, identifying areas for improvement that led to enhanced operational effectiveness.
- Collaborated with engineering teams to refine assembly specifications, ensuring alignment with industry standards and customer requirements.
- Championed the adoption of new assembly technologies, facilitating smoother integration and boosting team productivity.
- Established performance goals for employees and provided feedback on methods for reaching those milestones.
- Reduced waste and pursued revenue development strategies to keep department aligned with sales and profit targets.
- Launched quality assurance practices for each phase of development
- Streamlined and monitored quality programs to alleviate overdue compliance activities.
- Cultivated positive rapport with fellow employees to boost company morale and promote employee retention.
- Established key performance indicators for assembly operations, driving accountability and fostering a culture of continuous improvement.
- Managed and motivated employees to be productive and engaged in work.
- Accomplished multiple tasks within established timeframes.
- Maximized performance by monitoring daily activities and mentoring team members.
- Enhanced customer satisfaction by resolving disputes promptly, maintaining open lines of communication, and ensuring high-quality service delivery.
- Resolved staff member conflicts, actively listening to concerns and finding appropriate middle ground.
- Controlled costs to keep business operating within budget and increase profits.
- Cross-trained existing employees to maximize team agility and performance.
- Developed and maintained relationships with customers and suppliers through account development.
- Managed budgets effectively, ensuring optimal financial performance while investing in necessary resources for business growth.
- Achieved departmental goals by developing and executing strategic plans and performance metrics.
- Built high-performing teams through effective recruitment, onboarding, and talent development initiatives.
- Mentored junior team members for career advancement, fostering a pipeline of future leaders within the organization.
- Improved safety procedures to create safe working conditions for workers.
- Developed a strong company culture focused on employee engagement, collaboration, and continuous learning opportunities.
- Streamlined workflows by identifying bottlenecks in existing systems and implementing appropriate solutions.
- Reduced operational costs through comprehensive process improvement initiatives and resource management.
- Improved customer satisfaction scores by overhauling customer service protocols and training staff in customer engagement techniques.
- Boosted employee morale and reduced turnover through development and implementation of comprehensive rewards and recognition program.
- Fostered partnerships with industry leaders, enhancing company's reputation and creating new business opportunities.
- Facilitated team brainstorming sessions that led to innovative solutions for long-standing operational challenges.
- Led cross-functional teams to achieve project goals, fostering collaboration and innovation.
- Enhanced product quality by instituting rigorous quality control procedures, resulting in fewer customer complaints.
- Developed comprehensive risk management plan, minimizing potential disruptions to business operations.
- Enhanced team productivity by implementing agile methodologies, leading to more efficient project completion.
- Organized professional development programs for staff, leading to improved performance and skill sets.
- Planned, created, tested and deployed system life cycle methodology to produce high quality systems to meet and exceed customer expectations.
- Trained personnel in equipment maintenance and enforced participation in exercises focused on developing key skills.
- Identified and communicated customer needs to supply chain capacity and quality teams.
- Set aggressive targets for employees to drive company success and strengthen motivation.
- Developed detailed plans based on broad guidance and direction.
- Recruited, interviewed and hired employees and implemented mentoring program to promote positive feedback and engagement.
- Assisted in organizing and overseeing assignments to drive operational excellence.
- Successfully managed budgets and allocated resources to maximize productivity and profitability.
- Defined clear targets and objectives and communicated to other team members.
- Evaluated employee performance and conveyed constructive feedback to improve skills.
- Established team priorities, maintained schedules and monitored performance.
- Maintained positive customer relations by addressing problems head-on and implementing successful corrective actions.
Production Engineer-Lead (Wheelset & Bogie Assy.)
Bombardier Transportation India Pvt Ltd
05.2014 - 01.2021
- Operation & Process improvement
- Led cross-functional teams to optimize wheelset and bogie assembly processes, resulting in improved production efficiency and quality standards.
- Implemented advanced manufacturing techniques for wheelset assembly, enhancing operational throughput and reducing assembly time significantly.
- Mentored junior engineers in assembly best practices, fostering a culture of continuous improvement and technical excellence within the team.
- Developed and executed maintenance schedules for production equipment, minimizing downtime and ensuring consistent operational performance.
- Led cross-functional teams in executing strategic initiatives, significantly improving overall operational performance and coordination.
- Streamlined operational workflows by implementing process improvements, resulting in enhanced efficiency and reduced lead times.
Production Engineer (Wheel set assy.)
Chakradhari Wheels India (Pvt.) Ltd.
04.2012 - 04.2014
- Operation & Development
- Joint venture of M/S Lugcentrokuz & KLW Wheels Ukraine (Eastern Europe)
- Streamlined wheelset assembly processes, enhancing production efficiency and ensuring adherence to quality standards.
- Led cross-functional teams to implement process improvements, resulting in reduced assembly time and increased output.
- Developed training programs for new hires, fostering skills enhancement and promoting a culture of safety and quality.
- Conducted regular inspections of production equipment, identifying maintenance needs and minimizing downtime during operations.
- Performed root cause analysis and implemented corrective actions.
- Trained team on best practices to optimize production and improve quality.
Production Engineer (Press shop)
Casewell Drilling Services India (Pvt.) Ltd.
10.2010 - 03.2012
- Operation.
- Trained team on best practices to optimize production and improve quality.
- Led cross-functional teams to optimize press operations, resulting in improved workflow efficiency and reduced downtime.
- Implemented process improvements that enhanced product quality, contributing to increased customer satisfaction and repeat business.
- Developed and maintained production schedules, ensuring timely completion of projects while adhering to safety and quality standards.
- Resolved technical and quality issues by collaborating with customer, manufacturing, quality assurance, vendors and supplier personnel.
- Conducted root cause analysis on production issues, facilitating corrective actions that minimized equipment failures and operational disruptions.
- Trained and mentored junior engineers and technicians, fostering a culture of safety and continuous improvement within the team.
- Supervised entire production process and prepared proper documentation for dispatch.
- Implemented safety protocols that drastically decreased workplace accidents.
Education
Postgraduate (PG) course - Tool design
IDTR- Jamshedpur
01.2010
B.E - Mechanical
MPCT Gwalior – Affiliated to RGPV Bhopal
01.2009
Skills
Proficient in manufacturing of railway bogie frames, wheelsets & bogies
Accomplishments
- Internal Auditor for Quality Mgmt. System based on ISO -9001:2015 certified by TUV SUD South Asia Pvt. Ltd.
- Lean Six Sigma Yellow Belt certified by Vision Excellence Consulting Private Limited, Chennai.
- Revitalized the Nencki test bench functioning & production of 3 axle railway bogie testing along with OEM(Nencki) after making massive effort saving of 100 million INR equivalent to new setup cost.
- Set up new hydraulic brake testing facilities with OEM Hydac India to test allowable pressure drop less than 0.1 bar in 120 sec.
- Establish the complete tool list / range of non-bom consumables are used for production of bogie assy., paint shop & m/cing along with suppliers in coordination with the relevant purchasing dept., clients.
- Achieved all KPI’S in FY 2023-24 successfully i.e. (Production costs, delivery reliability, additional costs before and after delivery, Zero faults per bogie, productivity, response rate, hourly rate of the production unit, occupational health and safety, 3i investment)
- Programming of Bogie load testing at Nencki m/c of Sydney & Bangkok metro bogies saving of 1.2 million INR cost.
- Through put time (TPT) reduction of painting & assy. of bogies from 9 days to 6 days in Bucharest project.
- Productivity improvement of workers’ full time equivalent (FTE) from 136 hrs. to 145 hrs. in FY 2024 to reduce manpower requirement & improve efficiency.
- First article inspection (FAI) completed successfully of 3 axles EF09K Indian Railways bogies (Especially contract awarded by Central govt. for dedicated freight corridor to boost freight facility by locomotive 9000 HP)
- Production payment milestones 100% secured to improve the ALSTOM business performance.
- Cost saving in CI road map as per ALSTOM annual target.
- 5 to 10 % productivity achieved in EAC in QNGR & DMRC projects.
- Minimized the rejection during wheel press production as per yearly target <_ 1 %.
- Successfully manage Critical machines breakdown, rework of Bogie frames & assy.
- RFT bogies > 99 % and won trophy for best quality station.
- Trained the Technicians & Engineers in Critical machine – MAE Wheel press, Bogie press & Spring press machine.
- TPT improvement achieved in QNGR project to avoid the cost incurred as per budget.
- Recognized for creative problem resolution awarding by appreciation certificate.
- Reworked fabricated frames – End port cutting and reassemble to save cost of product realization – 285 Keuro.
- Save the Wheels rejection during wheelset manufacturing – 80 Keuro in QNGR project.
- Participation in I NOVE U autonomation in QNGR bogie assy. for hr. reduction & Safe working.
- 1 - Set up operation of Wheelset pressing accord. To follow requirement of Indian railway – IRS 19/93 (Part 1)
- Acquired the practical training of forging wheels, axles, heat treatment, machining & wheelset pressing, bearing assy. in Ukraine.
- Trained the leaders & technicians wheelset assy. at press machine, Ra measurement, material handing (heavy), elementary knowledge of lean work culture to improved productivity.
- Development of Tools & tackles, rolling turn table to transport parts from station to another without waiting.
- Design of machine tools & fixtures to improve productivity & reduce cycle time.
- Autonomous maintenance of machine regularly to maintain life cycle or avoided breakdown to improve production output at right time with right quality to customer.
TRAINING UNDERTAKEN
- 1. Wheelset Assy. Manufacturing Place- M/S Lugcentrokuz Private Joint Stock Company Ukraine-91 005, Lugansk, PO Box 1 (Eastern Europe) Duration:- One-month (August-September 2012)
- 2. Wheelset and Bogie Assy. Manufacturing: Bombardier Transportation (ALSTOM) Place- Siegstraße 27, 57250 Netphen Gmbh – Germany (Western Europe) Duration – One and half month (October – November 2014)
- 3. EN 13260 ,13261 & 13262 & IRS R-90/93(Part 1)
- 4. Shop floor management. 5-Operation management.
- 5. PPS, Autonomous maintenance (TPM) 7-SAP methodology
- 6. Its start with me (safety – Bombardier global)
- 7. Quality KPI’S.
- 8. Ethics and Compliance.
- 9. Safety KPI’S.
- 10. APQP, PFMEA, MSA & SPC – Quality tool & Time management.
- 11. Internal Auditor – ISO 9001 :2015 & Lean six sigma yellow belt (DMAIC Methodology)
Declaration
I assure you of the authenticity of the above-mentioned information & am sure to best my knowledge & belief.
Certification
Internal Auditor for Quality Mgmt. System ISO 9001:2015
Timeline
Lean Six Sigma Yellowbelt ( DMAIC Methodology)
09-2024
Internal Auditor for Quality Mgmt. System ISO 9001:2015
01-2023
Head of Production (Bogies & Components)
Siemens Ltd
06.2022 - Current
EPU - Manager (Wheelset & Bogie Assy.)
Alstom Transport India Ltd.
02.2021 - 06.2022
Production Engineer-Lead (Wheelset & Bogie Assy.)
Bombardier Transportation India Pvt Ltd
05.2014 - 01.2021
Production Engineer (Wheel set assy.)
Chakradhari Wheels India (Pvt.) Ltd.
04.2012 - 04.2014
Production Engineer (Press shop)
Casewell Drilling Services India (Pvt.) Ltd.
10.2010 - 03.2012
B.E - Mechanical
MPCT Gwalior – Affiliated to RGPV Bhopal
Postgraduate (PG) course - Tool design
IDTR- Jamshedpur