MANAS RANJAN MOHAPATRA
Assistant Manager- Manufacturing Engineering/ NPD/Industrialisation
Mysore
Summary
Accomplished engineering professional with expertise in manufacturing and process engineering, demonstrated at Automotive Axles Limited. Proven track record in leading new product development and optimizing gear operations. Skilled in AUTOCAD, SOLID WORKS and team leadership, ensuring compliance with IATF 16949 standards. Successfully improved OEE by 15% through strategic process enhancements.
Encouraging manager and analytical problem-solver with talents for team building, leading and motivating, as well as excellent customer relations aptitude and relationship-building skills. Proficient in using independent decision-making skills and sound judgment to positively impact company success. Dedicated to applying training, monitoring and morale-building abilities to enhance employee engagement and boost performance.
Overview
12
12
years of professional experience
2027
2027
years of post-secondary education
Work History
Assistant Manager - Gear Engineering (NPD / Manufacturing Engineering)
Automotive Axles Limited
07.2023 - Current
- Independently leading new product development and manufacturing engineering activities for major OEMs (Volvo, Ashok Leyland, and Marinara).
- Established and validated manufacturing processes for rear axles, tandem axles, and hub reduction drive gear sets, enhancing production efficiency.
- Optimizing gear hard operations (lapping, testing, SFT noise optimization), and performing inspections via Klingenberg P65.
- Designing work-holding fixtures, gauges, and tooling using AutoCAD for various gear manufacturing stages.
- Translating customer-specific requirements (CSR) into robust product and process specifications.
- Ensuring IATF 16949 compliance by maintaining PFD, PFMEA, Control Plan, PPAP, SPC, and MSA documentation.
- Collaborate with R&D, Quality, Production, and Procurement to improve manufacturability and technical standards.
- Managed supplier quotations, purchase requisitions, and facilitated cross-functional team (CFT) discussions to align on product feasibility.
- Plan and execute a technological roadmap, and introduce new methods, technologies, and equipment.
- Communicated with production, procurement, and other departments to streamline operations and resolve potential issues.
- Engineering: Manufacturing and Process Engineering, NPD, Spiral Bevel, and Hypoid Gear Engineering.
- Design: Fixture, Tooling, & Gauge Design, GD&T Interpretation, AutoCAD.
- Quality and Systems: PPAP, PFMEA, Control Plan, SPC, MSA, IATF 16949 Compliance.
- Operations: Production Planning, OEE Improvement, Cost Reduction, Supplier Development.
- Leadership: Team Leadership, Manpower Planning, New Machine Commissioning.
- Software: AutoCAD, MS Office (Excel, Word, PowerPoint).
- Conducted regular audits to ensure compliance with safety standards and regulations.
Operating Engineer / Team Leader - Production
American Axle Manufacturing Private Limited
08.2017 - 07.2023
- Coordinated shift manpower and production targets, enhancing OEE through continuous process improvements.
- Established Spiral Bevel and Hypoid Gear processes on Oerlikon and Klingenberg machines.
- Oversaw quality documentation (PPAP, Control Plan, PFMEA, SPC, SWCT) and facilitated ISO/TS 16949 audits.
- Achieved 100% compliance with shop-floor safety, quality, and productivity standards.
Operating Engineer - Gear Production
Spicer India Pvt. Ltd.
04.2015 - 08.2017
- Directed production output and manpower deployment, optimizing workflow in the gear department.
- Handled setup changeovers and troubleshooting, resolving daily production issues to maintain operational flow.
- Participated in Kaizen events, identifying process improvements for enhanced operational efficiency.
Technician trainee - Injection Mounding
Mathewson Automotive Technologies & Engineering
06.2014 - 03.2015
- Conducted quality inspections and analyzed production line defects to ensure product standards.
- Machine Operation & Setup
- Prepared raw materials for production to support efficient operations.
- Assisted toolroom team with mould cleaning and lubrication to maintain equipment performance.
Education
Bachelor of Technology - Mechanical Engineering
Biju Patnaik University
Diploma - Mechanical Engineering
Ramarani Institute of Technology (RIT)
Balasore, OdishaITI - Fitter
Almighty Technical Institute
Bhadrak, OdishaSkills
Operations management
Team leadership
Employee performance evaluations
Cost reduction
Problem-solving
Multitasking Abilities
Task delegation
Decision-making
Time management
Project management abilities
Multitasking and organization
Process improvement strategies
Inventory management
Teamwork and collaboration
Problem-solving abilities
Documentation and reporting
Accomplishments
- Successfully led programs for Volvo and Ashok Leyland involving complex gear sets.
- Spearheaded TRIAC to SPIRON conversion, significantly improving gear efficiency.
- Reduced gear cutting cycle time by implementing advanced pre-cut methods.
- Resolved critical noise issues in MS04, MS06, and RS120 gear models.
- Led a project to modify the lapping compound flow system across all lapping machines, resulting in a 150% reduction in cycle time, improved gear profile quality, and reduced transmission error.
- Redesigned pinion tooling to eliminate machine unavailability for SFT model gear sets, ensuring on-time delivery during customer urgency.
- Successfully led a project to redesign the clamping unit of the loaded contact machine, resulting in a setup time reduction of over 55%.
Languages
- English
- Hindi
- Odia
- Marathi
Timeline
Assistant Manager - Gear Engineering (NPD / Manufacturing Engineering)
Automotive Axles Limited
07.2023 - Current
Operating Engineer / Team Leader - Production
American Axle Manufacturing Private Limited
08.2017 - 07.2023
Operating Engineer - Gear Production
Spicer India Pvt. Ltd.
04.2015 - 08.2017
Technician trainee - Injection Mounding
Mathewson Automotive Technologies & Engineering
06.2014 - 03.2015
Diploma - Mechanical Engineering
Ramarani Institute of Technology (RIT)
ITI - Fitter
Almighty Technical Institute
Bachelor of Technology - Mechanical Engineering
Biju Patnaik University