Karan Sharma
Ambala
Summary
Dynamic Manufacturing operations leader with 11 years of experience in (Production/Quality) proven track record at Mahindra & Mahindra & Honda Cars India Limited, adept in Final line assembly and process planning. Excelled in manpower management, enhancing team performance and efficiency. Implemented Poka Yoke and 7 QC tools, signicantly reducing line rejections. Skilled in balancing strategic oversight with hands-on technical expertise.
Overview
11
11
years of professional experience
Work History
Deputy Manager in Assembly
Mahindra & Mahindra Limited
Ambala
09.2024 - Current
- Monitoring operational KPIs including Safety, Quality standards, cost optimization strategies, on-time deliveries and team morale.
- Managing Dismounting line operations
- Managed a workforce of 2 supervisors and 67 line associates.
- Implemented safety culture on the shop floor using HIRA, ROKO-TOKO, near miss reporting, and analysis.
- Oversaw activities involving manpower, machinery, materials, and processes.
- Producing production reports on a daily, weekly, and monthly basis
- Controlling line rejection through rework and the PDCA approach.
- Line balancing according to TAKT Time
- Conducting daily audits (Process and Quality) to check the standardization of the process.
- Scheduling and implementation of internal audits for Tool torque verification audit, Past defect countermeasures & other critical items
- Analysis of defects generating on line through Why Why & PDCA approach
- 5S, TPM, and POKA-YOKE, implementing the best practices on line side.
In-Process Quality
Mahindra & Mahindra Limited
Ambala
09.2023 - 08.2024
- Looking after all line quality gates (backend and dismounting) in the assembly department.
- Tracking and monitoring of all issues reported on the line side and Q-GATES.
- Responsible for reducing the reoccurrence of defects through various audits, Kaizens, PDCA, and the Why-Why analysis approach.
- HUT issues resolutions through a theme-based selection and resolution approach.
- Tracking and monitoring of all countermeasures and adherence by daily audits.
- Quick diagnosis, analysis, and treatment of market problems by teardown/reverse engineering analysis and detailed process know-how (Genba-focused approach) to ensure customer satisfaction.
- Weekly & Monthly quality review meetings with stake holders & senior management for issues tracking & resolution.
- Driving continuous improvement by implementing Kaizen, Poka Yoke, PDCA, PFMEA, and Quality Management for continuous improvement.
- Negative audits in process, and Q-GATES ensuring 100% inspection.
- Process & CTQ audits for adherence of all critical parameters.
- Functional, leakage, and other critical issues controlling and countermeasure adherence by daily, weekly, and monthly frequency-based audits.
- Decrease the rate of rejection and rework through PDCA approach.
- Preparation of daily, weekly, and monthly quality reports.
- Maintaining of Documents. (ALL CHECKSHEETS, INSPECTION SHEET, DEFECT TRACKING & MONITORING SHEET, PCR SUMMARY, TORQUE SHEETS)
- Root cause analysis of defects generating on line.
Associate Manager
Honda Cars India Limited
Bhiwadi
03.2018 - 09.2023
- Maintaining daily targets i.e.Safety, Quality, Cost, Delivery & Morale
- Looking after WIRING zone
- Handling the team of 75 number of associates
- Supervision for all activities related to 4M (Man, Machine, Material, and Method).
- Decrease the rate of line rejection by rework & PDCA
- Making and maintaining of documents (OPS, process sheet, PQCT, skill monitoring chart, operator control chart, torque sheet, L2 and L3 sheets).
- Allocated manpower to different workstations based on skill metrics.
- Performed routine assessments to monitor adherence to countermeasures at each workstation
- Skilled in car assembly processes
- Root cause analysis of defects generating on line
Team Associate
Harley-Davidson Motor Company India
Rewari
11.2013 - 03.2018
- Supervision for all activities related to 4M (Man, Machine, Material & Method)
- Handling the team of 12 number of line associates
- Making production reports on daily, weekly and monthly basis
- Cycle time study for best improvement
- Hands-on experience of assembling bikes and power trains.
- Organize regular team meetings, share information, manpower allocation to different work stations according to their skill metrics, address team and provide quality feedback
- 5S, TPM, CIS, implementation on line side
- Line balancing & PFMEA study
- Documentation (SWS, Control Plan))
- Defects Analysis.
Education
Diploma in Mechanical Engineering -
Satyam Polytechnic & Pharmacy College
05.2013
10th -
DAV Senior Secondary School
03.2008
Skills
- Quality Control
- Cost reduction
- Manufacturing Operations
- Final Assembly
- Process Planning
- 5S
- POKA-YOKE
Accomplishments
- 2 number of manpower reduced in process by implementing Kitting Concept.
- POKA-YOKE done by developing mandrel to preventing wrong bearing press in the frame body. Hence frame rejection is controlled. (Harley Davidson India Limited)
- Linking between the controls of air balancer and EIN punching machine. Hence rejection of engines reduced. (Harley Davidson India Limited)
- Linking between the applications of various torques in every workstation. Hence operator's motion is reduced and no occurrence of torque skipping. (Harley Davidson India Limited)
- Reduction in scratch related defects through theme based approach.
Languages
- English, Very Good
- Hindi, Native Speaker
- Punjabi, Native Speaker
Personal Information
Date of Birth: 03/13/92
Timeline
Deputy Manager in Assembly
Mahindra & Mahindra Limited
09.2024 - Current
In-Process Quality
Mahindra & Mahindra Limited
09.2023 - 08.2024
Associate Manager
Honda Cars India Limited
03.2018 - 09.2023
Team Associate
Harley-Davidson Motor Company India
11.2013 - 03.2018
Diploma in Mechanical Engineering -
Satyam Polytechnic & Pharmacy College
10th -
DAV Senior Secondary School
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