Arun Kumar Dhoundiyal
Rudrapur
Summary
Competent professional with 20+ years of experience in leading Manufacturing Operations Processes, Plant Management, CAPEX & Costing, New Product Development, Cost Control, Waste Elimination & Total Quality Management & Risk Assessment Studies with Six Sigma Black Belt. Improved Overall Operating Efficiency (OOE) through measures such as strategic thinking, proper planning and execution, commissioning and continuous improvements to avoid unplanned shutdown Experience in managing technically advanced, cost-efficient and state-of-the- art production systems; skilled in enhancing productivity, improving operational efficiency, quality & process effectiveness and cost reduction. Experience of working with key clients like Merino Industries Limited, Ashok Leyland, Tata Motors, Mahindra & Mahindra and Samsung India Electronics Defined project baselines by monitoring & controlling projects with respect to cost, resource deployment, time over-runs and quality compliance to ensure satisfactory execution of projects for client facilities Recommended continuous improvements through a mix of tools such as Six Sigma, Kaizen, 5S, TQM, Excellent interpersonal, communication and organizational skills with proven capabilities in team management
Overview
22
22
years of professional experience
1
1
Certification
Work History
Factory Head
Merino Industries Limited
11.2024 - Current
- Projects for capacity enhancement with continuous improvements through a mix of tools such as Six Sigma, Kaizen, 5S, TQM, Excellent interpersonal, communication and organizational skills with proven capabilities in team management.
- Budgeting and Cost Controlling: Preparing and managing budgets for various departments within the factory. Monitoring expenses, analyzing variances, and implementing cost-saving measures to optimize resource utilization and CAPEX utilization.
- Cost saving projects.
- Possess knowledge of Legal compliance, successfully negotiating with unions and resolving issues.
- Developing and implementing strategies to meet production targets, improve efficiency, reduce costs, and enhance overall performance of the factory.
Factory Head
TTK Prestige
Roorkee
11.2023 - 11.2024
- Managing Operations: Overseeing all aspects of factory operations including production, quality control, maintenance, and logistics to ensure efficient and effective functioning of the facility.
- Strategic Planning: Developing and implementing strategies to meet production targets, reduce costs, and enhance overall performance of the factory.
- Budgeting and Cost Controlling: Preparing and managing budgets for various departments within the factory. Monitoring expenses, analyzing variances, and implementing cost-saving measures to optimize resource utilization.
- Assuring Quality: Establishing and enforcing quality control measures to ensure products meet specified standards and customer expectations. Implementing continuous improvement initiatives to enhance product quality and reliability.
Manufacturing Head/Factory Manager
Escorts Ltd.
Faridabad
12.2018 - 10.2023
- Played a key role in achieving both top-line and bottom-line targets by closely monitoring and driving EBITDA growth from ₹325 Cr to ₹950 Cr.
- Supervising the machine shop, air brake shop, friction material shop, process & project engineering.
- Established quality standards, implementing stringent quality control systems for in process Quality matrix achieve 95% stat pass inhouse in all product segment.
- Liaising with team members to increase individual performance by setting realistic KPI’s.
- Interacting with senior management on projects to improve quality and increase profit margins by cost reduction & improving productivity.
- Directed end-to-end plant operations for a Tier-1 supplier to Indian Railways, ensuring seamless production, quality, and on-time delivery.
- Spearheaded lean manufacturing and continuous improvement initiatives, resulting in a 20% increase in operational efficiency.
- Ensured strict compliance with RDSO, IRIS, ISO 9001, and other railway-specific quality standards.
- Implemented robust quality control systems, reducing customer complaints and internal rejections by 30%.
- Successfully managed CAPEX and OPEX budgets while driving cost optimization across plant operations.
- Oversaw vendor development and supply chain alignment to support Just-in-Time (JIT) manufacturing for Indian Railways contracts.
- Championed digitalization and Industry 4.0 practices to enhance traceability, process control, and reporting accuracy.
- Played a key role in plant audits and approvals from Indian Railways and global OEMs.
- Drove employee training, safety compliance, and engagement, leading to improved retention and performance.
- Capacity enhancement of key products BMBS from 300 to 4000 numbers per month, Air Brake- from 50 to 250 numbers per day, Shockers- from 7000 to 13000 numbers per month.
- Played key role in NPD along with R&D and ensured timely delivery.
Divisional Manager
Ashok Leyland Ltd.
Pantnagar
06.2010 - 12.2018
- Successfully achieved production targets in vehicle assembly and vehicle testing shop operations.
- Ensured adherence to control plans (CP) to maintain and surpass quality standards.
- Mentored the team to excel in various company and plant initiatives, fostering continuous growth and development.
- Collaborated closely with senior management on projects aimed at enhancing quality and expanding market share.
- Pioneered continuous improvement and operational excellence initiatives such as Poka-Yoke, Kaizen, and 5S, driving significant enhancements in efficiency and effectiveness.
- Spearheaded the Quality Banner Project, benchmarking processes against global standards to achieve competitive advantage in SQDCM metrics through enhanced process consistency and efficiency.
- Demonstrated commitment to achieving manufacturing excellence by adhering to world-class manufacturing systems.
- Successfully managed vehicle assembly operations, exceeding production targets while upholding compliance with control plans to maintain top-tier quality standards.
- Developed programs aimed at improving operative engagement and fostering a positive work culture, including suggestion schemes to drive continuous improvement.
Manager - Manufacturing TCF Shop Nano Division
Tata Motors Ltd.
Pantnagar
05.2008 - 05.2010
- Emerged as a key member of the core team that established the Nano assembly shop including the erection & commissioning of the plant, start-up of production and establishment of standard production processes.
- Saved INR 5 lacs through low cost automation programs.
- Bagged Best Department Award for the implementation of MAX Kaizen.
Assistant Manager - Production Assembly Shop
Mahindra & Mahindra Ltd.
Haridwar
09.2007 - 05.2008
- Streamlined Daily Work Management (DWM) on the basis of Managing Points & Checking Points (MPCP) including analyzing and bridging gaps.
- Led smooth functioning of the assembly line achieving EWT of 400 minutes, monitored QA/QC & maintained line rejection cost below INR 5 per vehicle.
- Emerged as an active member of the CFT which prepared and implemented the complete document SOP and related travel cards & check sheets for introducing various variants of Champion 3-wheeler (0.75 T & 0.5T) as per MQS guidelines by using Kaizen & 5S.
- Supervised production processes of the Greenfield Unit & ramped up production from 20 to 118 vehicles per shift.
Engineer - Refrigerator Assembly & Testing
Samsung India Electronics Pvt. Ltd.
Noida
07.2005 - 07.2007
- Streamlined main assembly line producing 4000 refrigerators per day consistently achieved production & quality targets.
- Liaised with the maintenance department for completing all preventive maintenance jobs as planned. Supervised operation and minimized breakdowns and took part in the introduction of new models.
- Attained reduction in the cycle time from 16 seconds to 13 seconds per unit.
- Played a key role as Line In-charge and was promoted to Shift in Charge.
- Executed 2 Six Sigma projects of 3 months duration each and attained reduction of operational losses in the main assembly line by 50% and Reduction in test line defects by 70%.
G.E.T/ENGINEER(Production)
Anand Nishikawa Company Ltd.
Gurgaon
06.2004 - 07.2005
- Streamlined daily production targets with set parameters of quality/safety.
- Liaised with the maintenance department for completing all preventive maintenance jobs as planned Minimized breakdowns of moulds and ensured to line loss due to ANCO at customer’s end due to non-availability of parts/quality problems.
Education
B.E - Mechanical Engineering
DIT
01-2003
Skills
- Six Sigma Green Belt
- SAP PP Module End User
- Pro-3M
- 5S
- Kaizen
- Measurement
- GMES
- TPM
- 7 Wastes of Industry & PMS
- Stakeholder Management
- Team Management
- Leadership & Training
- Effective Leadership
- Budget management
- Quality control
- Lean manufacturing
- Operational efficiency
- Capacity enhancement
- Strategic planning
- Manufacturing improvement strategies
- Automation technology understanding
- Factory maintenance understanding
Accomplishments
- Best Plant of the Year, 2024, TTK Prestige
- 2 Time Chairman Excellence Award, Escorts Ltd
- Quality Improvement & Top 5%, Executive award Ashok Leyland Ltd
Languages
English
Hindi
Custom
Ten-day training in Samsung South Korea including Seminar on Effective Leadership
Certification
- Executive Program in General Management – XLRI Delhi
Timeline
Factory Head
Merino Industries Limited
11.2024 - Current
Factory Head
TTK Prestige
11.2023 - 11.2024
Manufacturing Head/Factory Manager
Escorts Ltd.
12.2018 - 10.2023
Divisional Manager
Ashok Leyland Ltd.
06.2010 - 12.2018
Manager - Manufacturing TCF Shop Nano Division
Tata Motors Ltd.
05.2008 - 05.2010
Assistant Manager - Production Assembly Shop
Mahindra & Mahindra Ltd.
09.2007 - 05.2008
Engineer - Refrigerator Assembly & Testing
Samsung India Electronics Pvt. Ltd.
07.2005 - 07.2007
G.E.T/ENGINEER(Production)
Anand Nishikawa Company Ltd.
06.2004 - 07.2005
B.E - Mechanical Engineering
DIT