Amruta Dalavi

Manufacturing Manager with extensive experience in New Product Development, Equipment Planning, and Capex Planning. Expertise in lean manufacturing and statistical analysis to improve production efficiency. Successfully implemented innovative solutions resulting in cost reductions, enhanced productivity, and improved quality. Experienced in coordinating cross-functional teams and utilizing project management tools for the effective execution of manufacturing engineering projects.

BSVI-Safe Launch

• To design the assembly process flow to manufacture BSVI engines, I designed the assembly process flow at the TCL-Phaltan Plant to manufacture BSVI B series engines, and I conducted value stream mapping of the assembly process of the BSVI engine
• a. 20+ major pieces of equipment installed, 107 fastening tools, and 113 failsafes implemented on the assembly line
• Developing, planning, maintaining, and executing project tasks
• Productivity Improvement
• 20 new workstations were added with a new conveyor line setup with an auto crank. New conveyor extension rotation machine, valve lash machines, and robot for engine transfer from
• Flywheel housing main line to new line
• The purging process for the B6.7 flywheel FIPG machine at the dual station was implemented to reduce the cycle time of the station, and the ergonomics score was reduced from 77 to 20

COBOT-mounted injector trim code scanning

• 2D matrix/QR code scanning of serial numbers and trim code traceability in MES for all types of injectors as per their installation locations on the cylinder head - Planning, technical discussion, trials, installation, commissioning, and handover of the project
• COBOT-mounted vision system for con rod and MB cap

Scope finalization with BU, supplier selection, negotiation, DAP, trials, system for ConRod, and MB installation and commissioning

Value Stream Mapping

• X104-NEXON - Reduced inventory, cycle time, and manpower utilization
• BSVI - Engine - Eliminated bottleneck stations, Assembly Line

Cost Reduction Project

• Development of a camshaft gear pressing machine fixture to suit all B series engine models with BSVI camshaft gear and cam thrust plate pressing, CAPEX saving 15 lacs
• Adapter press machine fixture to suit new launch multimodels, CAPEX saving 18 lacs
• TRIMS project: Localization of critical spares of the machine shop, CFSI

Ergonomic Risk Reduction Project

• Elimination of body pain (lower back and shoulder), operator squatting, and bending over by introducing a semi-automatic valve lash process reduced the ergo risk score from 66 to 25
• Eliminate ergonomic issues, such as exposure to hand injury due to sharp edges, and the deburring tool. Fatigue elimination occurs as each operator performs 500 deburring and lapping tasks in a shift, and there is an improvement in the Ergo Score from 34 to 5

Six Sigma Green Belt Project

• Deployment of the COBOT system for the PT Cup deburring process to convert the manual process into an automated process, reduce direct labor costs, improve RFT, and eliminate ergonomic risk