SAP PP & QM Module
KULDEEP RANA
Manager In Central Quality Assurance
Gurugram
Summary
16+ years of rich experience in production operations, Quality Planning, Auditing & Management in Vehicle Assembly operations. Hands on experience in equipment handling, production planning, Supplier process assessments, Process & Product improvements, Budgeting, manpower management, Implementing quality standards, operations efficiency, KANBAN, KAIZEN, TPM, IATF, QMS & Quality Circle, activities in manufacturing Vehicle assembly (Two Wheeler).
Overview
16
16
years of professional experience
6
6
years of post-secondary education
3
3
Certifications
2
2
Languages
Work History
Manager in Central Quality Assurance
Hero MotoCorp Ltd
Gurugram
05.2017 - Current
- Responsible for Part Quality of incoming BOPs / accessories within Plant as per specifications.
- Drive plant wide quality initiatives at supplier end for part quality & process improvements.
- Monitor & control supplier related Q Audits (QAV) based on control plan and ensure closure of findings with roadmap for overall product quality improvement.
- Monitor supplier quality performance (SQR) and initiating necessary actions within teams to improve the low performing suppliers.
- Monitor and control quality budgets for investments, personnel, laboratory, measuring equipment & digitization related initiatives across plants.
- Establish & organize Q education, trainings & Quality awareness sessions across plants based on TNIs of SQA cell.
- Part traceability & recall policy implementation at suppliers as well as at in-house products (end to end) inline with final vehicle assembly to mitigate market failure risk.
- Real time monitoring of CTQs implemented at critical suppliers for process assurance & control through IT based digital solution at HMCL.
- Hand-holding at suppliers / vendors for sustenance / continual improvement in product / process quality & monitoring the effectiveness through Audit / management reviews.
Deputy Manager in Vehicle Assembly Production
Hero MotoCorp Ltd
Neemrana
08.2014 - 04.2017
- Re-layout of Fuel Tank Sub Assy to implement single piece flow production by eliminating MUDA & MURI in process, resulting in cycle time reduction from 25 sec. to 18 sec.
- Scooter assembly line establishment & ramp up from green field to 1300 vehicle per/shift through.
- Implementation of Karakori kaizen of auto pallet rotation on joint conveyor to eliminate human fatigue in assembly shop
- Saving of 4 manpower per shift through redistribution / rebalancing of work using JIT.
- Continuously working on IMPs to increase productivity, process improvements, safety, Cost and overall OEE through effective implementation of JH pillar activities.
- Monitor & ensure adherence to ISO Standards like ISO 9001, ISO 14001, ISO 45001, IATF 16949 and controlling all related documents /compliances within the organization.
- First time right concept implemented in vehicle assy & achieved zero defect till 42 days.
- Support maintenance & tool engineering during PM and BM to reduce overall MTTR & improve MTBF of assembly shop through PM sheets & CLRI activity.
- Plan & control management information sheet, consumable budget, Personnel, Capital expenses, Overhead Budget related activities within plant.
Body Assembly Manager Production
Yamaha Motors India Pvt. Ltd
NOIDA
07.2013 - 08.2014
- Conveyor Assembly set-up as per Takt /Cycle Time for multi model production.
- Execution of pilot production to mass production of new R1 & FZ model with 12% improvement in productivity through re-layout of Calliper sub assy.
- Implemented cost saving project of Hand gloves consumption from 12 pair / day to 0 by providing chain slackness gauge in assembly line resulting in saving of 1.29 lac / year.
- Implemented zero defect assembly process on scooter line with 99.5% rider straight pass through separating tacking & tightening process of fasteners.
- Managing Productivity, Quality, Cost, Delivery, Safety & Morale in operation function.
- Leading, controlling & managing the performance of team members to ensure efficiency in process operations and meeting of organizational targets.
- Used critical thinking to break down problems, Quality issues, evaluate solutions and make decisions.
Assistant Manager Vehicle Assembly Production
Hero MotoCorp Ltd
Haridwar
06.2010 - 07.2013
- Managing a team of 180+ workforce in a shift
- Implemented TPM JH pillar activities to reduce motion losses in vehicle assembly line from 30 sec. / operation to 0 and saved 2 manpower per shift.
- Implemented cost saving project of ball race rejection of 200 pcs / day to 0 resulting in saving of 1.29 lac / year
- Improved impact gun life through inhouse repair initiative & implementation of lubrication unit (FRL), resulting in saving of 1.5 lacs / year
- Working on succession planning of the workforce, shift management activities, appraising the member’s performance with constructive feedback & resolve grievances to maintain high motivation level with in the team.
- Ensure requisite quality as well as establishing quality standard (zero defects of outgoing products) by using 7-QC Tools, POKA-YOKE, 3-G & WHY-WHY Analysis.
Production Engineer
Mikuni India Private Ltd
Neemrana
09.2009 - 06.2010
- Hands on experience of line setup for Throttle Body line from green field to mass production within 3 months
- Process validation / re-validation during initial setup of assembly line to minimize inprocess rejection
- Manpower calculation against variable setups, consumables requirement & budgeting, tooling cost calculation & budgeting
- Taking countermeasures to achieve Quality, Productivity, Delivery, Safety against the targets.
- Practiced lean principles, which led to improvements in workflow and quality and waste reduction.
- Collaborated with development teams, internal customers and product line management to verify delivery of desired quality requirements to customer.
Production Engineer
Motherson Sumi Systems Ltd
Gurgaon
12.2007 - 08.2009
- Ensure process parameters through layer audits and improving manual controls through visual management and trainings
- Implementation of Maruti Production System (MPS) on conveyor wire assembly line through reduction of MUDA resulting in productivity improvement 30% & rejection reduction 28%
- Train the associates on MSA, Gemba and Kanban system for defect free production
- Successful ramp up of New Engine Wire Harness of Wagon-R model from trail lot (PP1) to mass production & achieved productivity from 75sec / circuit to 30 sec/ circuit within 2 month.
- Identified risk mitigation actions to reduce injuries, accidents and hazards in production environment.
Graduate Engineer Trainee
Munjal Showa Ltd
Gurgaon
06.2006 - 12.2007
- Shift Planning as per daily / weekly Schedules of production in line with productivity targets
- Impart training to the workers on 5 “S”, One Point Lesson (OPL) & Kaizen Implementation
- Finding out root causes of in process quality defects and taking actions
- Changeover time reduced from 25 min to 3 min. on seam welding machine with the support of PE & Maint.
- Verified parts and materials through audit inspections and independent checks.
Education
B.E - Mechanical
Dronacharya College of Engineering
Gurgaon 08.2002 - 07.2006
Sr. secondary - Non Medical
D.A.V. Public School
Panipat 04.2001 - 03.2002
High School - Science Education
Anand Senior Secondary School
Kharkhoda, Sonipat 04.1999 - 03.2000
Skills
Supplier Process Assessment
Data Analytics
Internal Auditor
Problem Analysis
Line Balancing
7 QC Tools
Process Improvements
Supplier Upgradation
Line Set up
Layer Audits
TPM
Kaizen
Poka Yoke
SPC
Additional Information
- -Process Improvements -Quality Assurance / Audits -Operational Efficiency & Equipment`s Maintenance -Assembly Tactics & Standards -Inventory Norms & Controls -Manpower Management -New Product Development - Cost reduction & Budgeting
Software
MS Office -PowerPoint, Excel, Word
Lotus Notes
PLM
Auto CAD
Certification
Certified Lead Auditor IATF 1, Plexus International6949
Interests
Listening to Music
Reading books
Timeline
Certified Cost of Quality Expert, CII
01-2021
Manager in Central Quality Assurance
Hero MotoCorp Ltd
05.2017 - Current
Certified Lead Auditor IATF 1, Plexus International6949
12-2015
Certified 3rd party Auditor, Plexus International
12-2015
Deputy Manager in Vehicle Assembly Production
Hero MotoCorp Ltd
08.2014 - 04.2017
Body Assembly Manager Production
Yamaha Motors India Pvt. Ltd
07.2013 - 08.2014
Assistant Manager Vehicle Assembly Production
Hero MotoCorp Ltd
06.2010 - 07.2013
Production Engineer
Mikuni India Private Ltd
09.2009 - 06.2010
Production Engineer
Motherson Sumi Systems Ltd
12.2007 - 08.2009
Graduate Engineer Trainee
Munjal Showa Ltd
06.2006 - 12.2007
B.E - Mechanical
Dronacharya College of Engineering
08.2002 - 07.2006
Sr. secondary - Non Medical
D.A.V. Public School
04.2001 - 03.2002
High School - Science Education
Anand Senior Secondary School
04.1999 - 03.2000