Madhu Shankar B
Chennai
Summary
Dynamic Senior Production Engineer with a proven track record at Daimler India, excelling in process optimization and lean manufacturing. Achieved a 10% reduction in production costs through innovative problem-solving and effective team collaboration. Committed to safety compliance and quality operations, fostering a culture of continuous improvement and operational excellence.
Overview
14
14
years of professional experience
Work History
Senior Production Engineer
Daimler India Commercial Vehicles Pvt. Ltd.
Chennai
08.2017 - Current
- Managed end-of-line truck testing operations, conveyor setups, and production scheduling.
- Implemented 4M management principles and lean practices across all assembly processes.
- Monitored hourly SQDCM metrics, leading real-time corrective actions for continuous improvement.
- Troubleshot mechanical and electrical breakdowns, performing root cause analysis and corrective measures.
- Performed root cause analysis of production problems and identified corrective actions.
- Trained operators on proper use of machinery and safety protocols in the workplace.
- Ensured compliance with regulatory requirements regarding health, safety, hazardous materials, fire prevention and environmental protection.
- Coordinated with vendors to ensure timely delivery of parts and materials for production operations.
- Conducted regular maintenance checks on production machinery to ensure optimal functioning.
- Implemented Lean Manufacturing principles throughout the facility for increased productivity.
- Monitored quality control procedures to maintain product standards across all stages of the production cycle.
- Developed test plans and conducted tests to evaluate prototype designs before implementation into production lines.
- Identified cost saving opportunities through process optimization initiatives.
- Supervised daily operations to ensure full machine utilization and raw material availability.
- Prepared and maintained SOPs, work instructions, and inspection checklists for production processes.
- Coordinated with cross-functional teams for new vehicle model launches and proto builds.
- Conducted quality reviews at all production stages to uphold standards.
Production Engineer
Tata International DLT Pvt. Ltd.
Pune
04.2016 - 08.2017
- Led end-to-end production for Tipper, Trailer, and Car Carrier vehicles.
- Established new manufacturing plant for Car Carriers by planning and installing machinery and tools.
- Designed process layout and optimized workflows to enhance operational efficiency.
- Coordinated with civil, electrical, and utility teams to ensure infrastructure readiness.
- Recruited and trained operators and technicians for successful pilot production.
- Supervised welding, sub-assembly, and fitment operations across multiple platforms.
- Implemented process standards, SOPs, and WIs for car carrier builds to ensure consistency.
- Created detailed reports on production performance and made recommendations for process changes.
- Monitored trial runs to identify defects and ensured ramp-up to volume production.
- Developed and implemented production processes to increase efficiency and reduce costs.
- Implemented lean manufacturing techniques such as 5S, Kaizen, Kanban, to reduce waste and improve productivity.
- Designed jigs, fixtures, tools, gauges and other equipment needed for the efficient manufacture of products.
- Prepared technical documents including user manuals, installation guides, test protocols.
- Performed regular maintenance checks on machines used in the manufacturing process.
Executive Engineer
Tranztar Commercial Vehicle Applications Ltd.
Bhuj & Chennai
08.2013 - 04.2016
- Managed production line operations for Tipper bodies, Trailers, and Special Purpose Vehicles.
- Supervised fabrication, welding, and assembly activities to ensure quality and safety compliance.
- Implemented lean practices to reduce cycle time, rework, and material waste.
- Coordinated fixture planning, layout setup, and manpower allocation for efficient operations.
- Conducted in-process quality checks to maintain adherence to standard work procedures.
- Participated in new model development and ramp-up of new tipper/trailer variants.
- Trained operators on Welding Procedure Specifications and safe welding practices.
- Interfaced with design and quality teams to resolve issues and enhance product quality.
Diploma Engineer Trainee
AMW Motors Ltd.
Bhuj
06.2011 - 08.2013
- Supported manufacturing processes for tipper and trailer vehicle assembly.
- Assisted in chassis fitting, sub-assembly welding, and body mounting operations.
- Participated in line setup and production trials for new trailer variants.
- Carried out fixture inspections, tool verification, and ensured quality compliance.
- Learned and applied 5S, TPM, and basic quality tools during daily operations.
- Recorded defects, coordinated with the QA team, and ensured proper rework closure.
- Involved in day-to-day production planning, material flow tracking, and job card updates.
- Supported senior engineers in improving cycle time and reducing idle time in trailer builds.
Education
B.E. - Mechanical Engineering
Indian Institute of Industrial Engineering, Mumbai University
Navi Mumbai12-2024
Diploma - Mechanical Engineering
Thiagarajar Polytechnic College
Salem01.2011
Skills
- Production and maintenance
- Safety compliance
- Process improvement
- Process optimization
- Lean manufacturing
- Problem solving
- Value stream mapping
- Waste reduction
- Production management
- Cross-functional collaboration
- Quality and safety operations
- Cost optimization
- Training and development
- Team collaboration
- Effective communication
- Problem-solving skills
- 5S methodology
Awards
GOLD Award in ICQCC Competition 2024 in Sri Lanka., GOLD Award in CQFI Competition 2023 in Chennai, Bagged Cash Bonus by implementing Industrial wheel alignment and reduced cycle time in Poppet valve setting., 3rd Prize in CII Competition Chennai, EXCELLENCE AWARD in NCQCC Competition 2024 in Nagpur
Languages
English, Hindi, Tamil
Affiliations
- Spearheaded the new plant setup for Car Carrier Manufacturing, from layout planning to pilot production, enabling successful ramp-up within target timelines
- Played a vital role in tipper and trailer production optimization, reducing cycle time, and improving quality consistency through lean tools and process audits
- Led cross-functional teams in implementing industrial wheel alignment, resulting in improved accuracy and significant cycle time reduction, recognized with a cash bonus award
- Actively contributed to continuous improvement initiatives using 5S, Kaizen, and TPM in assembly and testing operations
- Regular trainer and mentor for new joiners in SOP adherence, safety practices, and welding procedure monitoring
- Received appreciation for consistently exceeding SQDCM metrics in end-of-line vehicle testing and quality KPIs
Languages
Tamil
First Language
English
Upper Intermediate (B2)
B2
Hindi
Beginner (A1)
A1
Accomplishments
- Led cross-functional teams in implementing industrial wheel alignment, resulting in improved accuracy and significant cycle time reduction, recognized with a cash bonus award
- Represented Daimler India at national and international quality forums:
š GOLD Award ā ICQCC Competition 2024, Sri Lanka
š GOLD Award ā QCFI Competition 2023, Chennai
š Excellence Award ā NCQC 2024, Nagpur
š„ 3rd Prize ā CII Quality Competition, Chennai
Timeline
Senior Production Engineer
Daimler India Commercial Vehicles Pvt. Ltd.
08.2017 - Current
Production Engineer
Tata International DLT Pvt. Ltd.
04.2016 - 08.2017
Executive Engineer
Tranztar Commercial Vehicle Applications Ltd.
08.2013 - 04.2016
Diploma Engineer Trainee
AMW Motors Ltd.
06.2011 - 08.2013
B.E. - Mechanical Engineering
Indian Institute of Industrial Engineering, Mumbai University
Diploma - Mechanical Engineering
Thiagarajar Polytechnic College
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