ALOK KUMAR
Faridabad
Summary
Strategic Chief Manager known for high productivity and efficient task completion. Possess specialized skills in operational strategy, team leadership, and financial management. Excel in communication, problem-solving, and adaptability, ensuring seamless operations and team cohesion in fast-paced environments.
Overview
18
18
years of professional experience
Work History
Chief Manager Manufacturing (Assembly, Paint & Testing)
ESCORTS KUBOTA LTD.
03.2019 - Current
- End-to-End Ownership of Assembly, Paint & Testing Operations
- Lead and manage all shop floor activities across final assembly, paint shop, and testing of construction equipment like backhoe loaders, compactors and cranes, ensuring adherence to takt time, quality standards, and safety norms.
- Drive daily, weekly, and monthly production planning in coordination with PPC, SCM, and R&D teams to ensure on-time delivery and smooth product flow across all value streams.
- Ensure zero-defect manufacturing by enforcing stringent quality control at every stage—assembly, painting, and dynamic testing—while driving continuous improvements (Kaizen, Six Sigma, Poka-Yoke) to eliminate non-value-added activities.
- Lead readiness for new product introductions and engineering change notices (ECNs), including tooling, process trials, layout modifications, and operator training to ensure smooth integration with minimal disruption.
- Manage a multi-skilled team of engineers, supervisors, and technicians. Drive skill development, performance metrics, cross-functional alignment, and shop floor discipline to build a high-performance culture across all functions.
- Manufacturing (Construction Equipment)
- Improved Overall Equipment Effectiveness (OEE) by 30%
- Reduced Vehicle Rework and Testing Failures by 40%
- Executed On-Time Launch of New Product Lines (Excavators / Loaders)
- Reduced Takt Time by 20% Through Line Balancing and Modular Assembly
- Achieved 100% Compliance in ISO, IATF, and Customer Audits
- Established In-House Dynamic Testing Track for Performance Validation
- Launched Digital Production Monitoring System (ANDON, OEE, Defects)
- Achieved 20% Reduction in Paint Material Wastage
Manager (NPD/Assembly/Testing/Paint Shop)
TII-GROUP GMBH
07.2017 - 03.2019
- Established End-to-End Production Line for Hydraulic Trailers & Heavy Trucks
- Successfully set up and stabilized the complete Assembly, Paint, and PDI operations from ground zero, including layout planning, equipment installation, SOPs, and manpower deployment.
- Implemented lean line balancing, parallel processing, and process re-engineering across assembly and paint operations, significantly improving throughput and delivery timelines.
- Strengthened in-process quality systems, introduced layered audits and robust PDI standards, leading to zero field failures and 100% customer satisfaction over 9 months.
- Led the design and implementation of an in-house paint booth and curing system, reducing outsourcing dependency, improving turnaround time, and saving 30% on paint-related costs.
- Effectively managed diverse and customized build requirements through modular planning, cross-functional coordination, and rapid changeover systems, ensuring on-time delivery of all special application vehicles.
- Farm Division is part of the GERMAN TII-GROUP and is the company among the top special Transport manufacturers in the World.
Assistant Manager
ASHOK LEYLAND LTD.
02.2011 - 06.2017
- Lead end-to-end operations of cab trim assembly for buses and trucks.
- Ensure daily production targets are met with adherence to takt time and SOPs.
- Drive process standardization and implementation of best assembly practices.
- Oversee the complete PDI process for final vehicles before dispatch.
- Ensure compliance with customer-specific and company quality standards.
- Manage a large team of supervisors, technicians, and operators across shifts.
- Coordinate with PPC, Quality, Logistics, and Maintenance for smooth line operation.
- Ensure adherence to IATF 16949, ISO 14001, and OHSAS standards.
- Lead Kaizens, 5S implementation, and waste elimination (Muda) projects.
- Achieved 20% Improvement in First Pass Yield (FPY)
- Reduced Vehicle Rework and Rectification Time by 35%
- Implemented End-to-End Digital PDI Checklist System
- Enhanced Line Productivity by 18% Through Lean Initiatives
- Flawless Execution of New Model Launches (AVTR Series)
Senior Officer
TATA MOTORS LTD.
05.2007 - 01.2011
- Supervision of cab trim assembly line operations to meet daily production targets.
- Allocation and management of manpower based on skill matrix and line balancing.
- Ensuring adherence to Standard Operating Procedures (SOPs) and safety norms.
- Monitoring in-process quality and implementing corrective actions to reduce rework.
- Conducting Pre-Delivery Inspections (PDI) as per company and customer checklists.
- Identifying and resolving defects before vehicle clearance and dispatch.
- Driving 5S, TPM, and lean manufacturing initiatives on the shop floor.
- Achieved Zero Defect Dispatch for Consecutive 3 Months
- Reduced Vehicle Rework by 40%
- Improved Daily Production Output by 15%
- Implemented 5S and Visual Management System Across Assembly Line
- Executed Model Changeovers with Zero Line Loss
Education
B. Tech. - Mechanical Engineering
Diploma - Automobile Engineering
Skills
- Assembly operations
- Lean manufacturing
- Production planning
- Process improvement
- Team leadership
- Effective communication
- Cross-functional collaboration
- Innovation management
- Strategic planning
- Cost control
- Business intelligence
Perceived Strength
- Desire to learn in every sphere of my life and strong will power
- Steady in Crisis management
- Decision Maker
- Balanced Behaviour
Training
- Delhi Transport Corporation Basic Service training at Delhi
- General and Advanced Training conducted by Ashok Leyland at their works
- Introduction to the concept of Kaizen and 5S conducted by Tata Motors
- Training on Conflict Management
- Training on Quality Circle organized by QCFI
- Training on Internal Auditor Program of TS 16949:2007
- Training of LSS (Lean six sigma)
- Training on VSM
- Training on COPQ
- Training on Automation and LCA (Low Cost automation)
- Training on DWM
- Training on Damming principles
- Training on Basic & advance Assembly concept
- Training on Basic & advanced Quality management Tools
- Trained in Office 365 AI Tools
- Trained in Advance Excel and Power BI
- Trained in TABLU
- Trained in Advance Powerpoint Tools
- Trained In SQL
- Trained in Artificial Intelligence Integration in daily Routine
Languages
English
Proficient
C2
Hindi
Proficient
C2
Personal Details
- Date of Birth: 07/01/87
- Marital Status: Married
Hobbies and Interests
- Sports
- Listening to music
CTC
30 lakhs PA
Disclaimer
I hereby declare that all the statements made in this resume are true, complete and correct to the best of my knowledge and belief.
Timeline
Chief Manager Manufacturing (Assembly, Paint & Testing)
ESCORTS KUBOTA LTD.
03.2019 - Current
Manager (NPD/Assembly/Testing/Paint Shop)
TII-GROUP GMBH
07.2017 - 03.2019
Assistant Manager
ASHOK LEYLAND LTD.
02.2011 - 06.2017
Senior Officer
TATA MOTORS LTD.
05.2007 - 01.2011