Kamal Kumawat

• The Company boasts of an extensive product portfolio which includes Major OEM – JCB -UK, BMW, JLR,
  DANA, GKN, MERITOR, OGNIBANE, ETC. Backed by its diversified product basket like – Dump End, End Cap, Tow Hooks, Knuckles, etc, the Company caters to different automobile segments, including Passenger Vehicles, Commercial Vehicles, Agricultural machinery, Off-loaders and Industrial vehicles,
  among others.
• Achievements:
  Procurement and development of New Tooling and Fixtures (Hydraulic parts – Dump End and END Cap) for JCB – UK – Phase 2 and Phase 3.
  Procurement and development of New Tooling and Fixtures for -Companion Flange - DANA and MERITOR.

• SIAC SKH India Cabs Manufacturing Pvt. Ltd. (SIAC SKH) is a 50-50 Joint Venture between SKH and SIAC SPA of Italy. The company currently manufactures fully trimmed cabins with Shower test and electrical test for JCB INDIA, CNH and Caterpillar.

Roes and Responsibilities:

• Sourcing of Raw Material, Sourcing of WA / GA Proprietary parts, In-direct Material, Development of Sheet metal parts
• Green field projects establishments, SOP and System implementation for Stores and Purchase.

Achievements :

• Development and procurement for new model ramp up from 20 cabins per day to 80 cabins per day without shortages.
• Benchmark by handling Cabin production assembly line from 4 cabins per day to 12 cabins per day with same resources.

JBM J5 is Major Sheet metal Company having Joint venture with Maruti Suzuki India Ltd (MSIL)

• JBM Group Having 54 plants across India and Abroad
• JBM – J5 Gujarat plant is one of the most automated plant with state of art Robotic sheet metal Press shop and Robotic Spot welding, Robotic Nut welding, Robotic stud welding and Robotic Assembly plant
• Major Parts are Rear Axle Assy., Dash component, Side sill, Cross member comp., Etc.

Roles and Responsibilities:

Mentored a group of 6 people ( 2 Diploma Engineers & 4 B-Tech)

• Sourcing of Raw Material–CR/HR Coils from 0.7 mm to 4 mm Thickness in various sizes
• Major Suppliers – Imported JFE / NIPPON, Domestic – TATA Steel, TSPDL, JSW, POSCO & ESSAR
• Sourcing of BOP items, Direct Material – Sourcing of Indent based items. Civil Contracts and Capital Goods Purchase – Press Machines upto 3000 Ton, Welding and Assy. ROBOTS, Automations and Imports
• Development of BOP Sheet metal parts for YRC-HB & YRC Minor.
• Green field projects establishments and Project Procurement as per On Site requirements

Achievements:

• RM job Work (Coil Slit / Blanking) Transportation cost Saving – Yearly 35 lacks
• Development of all BOP for YRC-HB (Baleno) line as per schedule for Final SOP – Dec-2018.

• Headed The Import Purchase (OEM - Ball Plant for Major Bearing plants - SKF, FAG, TATA, NEI, TOYOTA)
• Roles and Responsibilities: (Two plants for three shift)
• Mentored a group of 13 people (9 Diploma Engineers & 4 casuals)
• Direct and Indirect Purchase:
• RM - Import
• Import of Raw Material Wire Rods /coils from Ascometal –FRANCE (30 MT/Month)
• Import of Raw Material Wire Rods /coils from Dong Bang (POSCO) – S
• KOREA, Dongbo (POSCO) –S
• KOREA, Hunmi Resources (POSCO)– S
• KOREA (400 MT/Month)
• Import of Raw Material Wire Rods /coils from Metal One-JAPAN, Mitsui-JAPAN, Daido / Kobe – JAPAN (200 MT/Month)
• Import of Raw Material Wire Rods /coils from Dalian – CHINA
• (200 MT/Month)
• Import of Bakelite Grinding Wheels Lapping wheel from Noritake– Japan
• Import of AVIKO Make continuous and automatic sorting and inspection machines from Italy.
• Custom Clearance and payments of Import Suppliers as per LC Norms
• Tracking the Import Shipments and timely Duty Payment to Customs
• Ensuring CEPA Certification to get the Import Duty benefits
• Development: development of Cold Forging (Header) - Dies, Punch, and Cutters for all Sizes

• Products Managed: Tractor from 20 HP to 60 HP
• Headed following 4 Commodities: (210 Tractor per day in three shifts)
• Mentored a group of 8 people (6 Diploma Engineers & 2 GET’s)
• Forging: F D Gear-Milestone Gears, Rear Shafts- Emson Gear/Happy Steel, Bavel Gear and Pinion – Sadhu forgings, Gear shifter Forks- Dawn Motors, Lift Arms- Emson tools / Dawn Motors
• Bar Stock : Gear Shifter rod, G S rod RG, Fasteners, Brake mechanism, linkage assey
• Others
• Semi- Proprietary: Radiators-TATA TOYO/Standard Radiators, Wiring harness - MSSL, Instrument cluster-Pricol / Veethree / Minda, head lights – Hilux / Neolight / Minda/ Lumax, Tails Lights-Hilux, Rubber hoses-Belmont Rubber, gaskets- Cooper, Stickers- Craftsman, Steering Wheels-PMP/Hilux, Plastic Fuel Tanks-COSMOS & so on
• Sheet Metal : Front axle- Windals & Windals, Battery Cover, Air Filter, Exhaust Muffler, Hood, Fender & so on
• Scheduling of items as per BOM and the Daily Production plan
• Scheduling of Items for Spare Parts Division (SPD)
• Actively Participating with Team in Monthly Inventory in stores
• Ensure Quality approved parts on Assembly line / stores
• Monitoring and circulating Supplier Ratings to suppliers and get the Action plan
• Timely Payments to suppliers as per PO norms, and monitor Hundi and payment credits
• Maintain 3 Days stock and replenish the stocks
• Ensured fulfilment of the requirement of SPD (Spare Parts Division) Performance
• New Supplier Development – Zero Based Costing, PPAP Approval, Pilot Bach Approval
• Smooth Hand over of new Developed parts for Production and no obsolete items due to this
• Smooth implementation and documentation for change over to regular production
• Timely Supplier visit to ensure the Delivery as per new increased plan and capacity enhancement of Suppliers
• Vendor Upgradation by Providing Additional Financial loans to increase the Capacity and quality of the Products
• Achievements:
• Achieved Zero Line Stoppage due to material Shortage in the Tenure of service
• Upgraded 40% suppliers from B to A category (Quality/Delivery)
• Supplier Quality Rating Drastically Improved from 60,000 PPM to 5000 PPM
• Successfully developed 35 components at new supplier base / Alternate Sourcing
• Achieved 100 % requirement of Spare Parts Division on monthly basis
• Successfully Implementation of Plastic Fuel tank from COSMOS
• Benchmark for Smooth ER and New development hand over documentations
• Adherence of the SOP and Deployment of the Policy
• Periodic Review of KRA and MOP’s
• Steered initiatives towards implementation of Supplier Kanban & certification of ISO-14001:2004
• No major and Minor NC during ISO-14001:2004 certification audits.

• Products Managed: Tractor from 20 HP - 60 HP
• Headed the Entire SCPC Department
• Production Planning / Buying / Store / logistics
• Team of 34 members - 5 Engineers & 29 Casuals
• Major Commodity like Engine, Transmission, Hydraulics, Sheet Metal – (Hood, Fender, Front Axle and Dead Weight, Fuel tanks, Exhaust Muffler, battery Box), Tire and Tube, Radiator, Battery, Wiring Harness, Lights and Instrument Clusters
• Maintaining 3 Days stock and replenish the stocks of major Aggregates
• Carryout Monthly inventory to avoid Material Variance and shelf life of store items / BOM items
• Supplier KANBAN implementation of all Direct Buying items
• KAIZEN, OIT and CIT for Improvement Culture for Deming Awards
• Ensure the 3 Days PULL DEMAND methodology to minimize the Finished Goods inventories
• Just in Time Delivery as per plan of major Aggregates like Engine, Transmission and VTU’s
• Training and Development plan & R3 CONCEPTS for Staff members
• Organize the KAIZEN quiz, Akaraman Mela for new Improvement initiatives
• Achievements:
• Awarded with the ‘Mahindra Yellow Belt’ for initiating logistics cost saving (Engine transportation and layout of Fixture) of INR 78 Lakhs/Annum
• Attended the Supplier Development Training Program (15 days, (Mahindra Institute of Quality)-Nasik under Prof. K. Shimo Yamada San, Successfully developed 51 components at new Suppliers base / alternate Sourcing & converted 85 components into DOL/ 2 bin System for C-class Items
• Implemented 3 PL concept in 27 components to reduce the transportation cost INR 4.41 Lakhs
• Successfully covered all 129 Components into the Supplier KANBAN Process
• Innovated and implemented Slim Cuboid concept to reduce the on-line storage on assembly line
• Successfully participated in Deming projects & achieved by getting JQM-2007
• Reduced inventory level of raw material inside the plant from 12.4 days to 6.45 days
• Certified Internal Auditor of TS-16946, ISO 14001 and OHSAS-18001
• No major and Minor NC during ISO-14001:2004 and OHSAS 18001:2004 certification audits.

• Products Managed: LHD & RHD of TATA – 709 Starbus and Ashok Leyland Low Floor Bus
• Managed the entire purchase functions of raw material & proprietary items from TATA Approved suppliers
• Procurement of Major RM – CR Sheet and MS Sheet of different Thickness – From TATA, SAIL, JINDAL, JSW, etc
• Procurement of Aluminum Profiles and Pipes of different sizes.