Manish Singh

• Company Overview: MAT Brakes India is among India’s largest OEM brake pad manufacturers and a subsidiary of MAT Inc. (USA), serving global brands such as GM, Ford, Bosch, Volvo, Land Rover and Delphi etc.

Key Responsibilities

• Leading complete Brakes Shoe Line & PV Lining (Extrusion) Production ensuring seamless 3-Shift operations.

• Meeting daily production targets, manpower deployment & machine readiness.

• Monitoring KPI metrics: OEE, Rejection %, Downtime, Hourly Production, Cost per part.

• Strict compliance with SOPs, ISO/TS standards & safety protocols.

• Implementing Lean tools (Kaizen, SMED,5 Why, Fishbone) for line balancing, takt time improvement, and bottleneck elimination.

• Handling customer concerns, CAPA & 8D preparation and audit readiness.

• Coordinating with Quality, PPC, Maintenance and Stores for smooth material flow.

• Driving continuous improvement culture by leading kaizen & QIP events.

Achievements:

• Improved Brakeshoe production by 50% (3,200 → 4,800 sets/day) through bottleneck elimination and targeted kaizen improvements.

• Increased PV-Lining output by 25% (8 km → 10 km/day) by redesigning the oven hat for enhanced heat efficiency.

• Saved 6 manpower by optimizing the printing process using a rotating fixture.

• Achieved 18 manpower savings and increased glue coverage from 65% to 80%through glue-process optimization and roller modification; awarded QIP 1st Runner-Up (2025).

• Reduced A-Dimension Out defect by 80% (0.78% → 0.16%) using tooling-based corrective actions; received Best QIP Award – MAT India.

• Independently managed complete Tool Room operations for CVP, PVP, Rigid & Flexible PV-Linings, M-CVP and Brakeshoe sections, ensuring seamless support to production.

• Prepared and controlled yearly capex and consumable budgets, maintaining expenses strictly within approved limits.

• Executed preventive & corrective maintenance of all tool room machines (lathe, milling, grinding, VMC/CNC support), ensuring maximum uptime and precision.

• Planned and reviewed daily machine loading, prioritising workload distribution and optimising resource utilisation.

• Led TPM initiatives across CV-Pads section and reducing breakdown frequency.

• Carried out new die manufacturing, validation and offloading to vendors with stringent quality follow-up.

• Maintained complete tool history cards, maintenance logs, and spare management for accurate traceability and planning.

• Conducted breakdown analysis (5 Why, CEDAC) and implemented permanent corrective actions for repeated tool failures.

• Oversaw the precision manufacturing of tooling components, jigs, fixtures, and gauges, with follow-up with suppliers for offloading work.

• Managed spare parts, consumables and preventive maintenance schedules, ensuring uninterrupted production operations.

• Coordinated closely with Quality, Production & Maintenance teams for troubleshooting, trials and process stabilisation.

• Implemented 5S, Kaizen, Poka-Yoke and Six Sigma practices, strengthening efficiency, safety and workplace organisation.

• TOOL ROOM – KEY ACHIEVEMENTS

• Increased CV-Pads production by 10% (55 → 60 sets/machine) by resolving punch-stuck issues and optimising tooling.

• Permanently resolved recurring Y-clamp breakage issue on Brakeshoe line, achieving ₹24 lakh/year cost savings.

• Implemented a robust Preventive Maintenance system, reducing tool breakdown frequency from 1.35% to 0.45% (Avg.).

• Delivered ₹15 million annual savings by optimising CVP tool heating—replacing 1.3 kW machine heaters with 400 W direct tool heaters.

• Achieved 5% yearly savings by optimising Tool Room capex, reducing consumable usage and lowering per-part tooling cost.

• Company Overview:

A certified ISO 13485 orthopedic implant manufacturer specializing in plates, screws, instruments and hip prosthesis. Known for precision CNC/VMC machiningand medical-grade SS316L/Titanium manufacturing.

• Key Responsibilities:

• Prepared job cards, routing sheets & material issue plans as per customer orders.

• Ensured availability of SS304 / SS316L / Titanium raw materials through continuous follow-up with Purchase.

• Monitored daily machining output, cycle times & dimensional accuracy across CNC, VMC, Plate, Screw & Hip-Prosthesis sections.

• Managed critical tooling inventory (drills, dies, cutters) and resolved machining issues related to tool wear, fixturing & surface finish.

• Coordinated with Maintenance for breakdowns, preventive maintenance & calibration, ensuring stable machine performance.

• Company Overview:

A leading Tier-1 automotive components manufacturer supplying wiring harnesses and moulded/electronic parts to major OEMs. Focused on tooling, automation and high-volume production quality.

• Key Responsibilities:

• Managed shift-level tool room operations, overseeing mould/tool breakdowns, die-setting and quick restoration to minimize downtime.

• Conducted breakdown analysis (MTBF/MTTR) and executed corrective actions to improve tool reliability and reduce repeat failures.

• Performed preventive maintenance of moulds and tools, including blade inspection, alignment checks of assembly jigs & fixtures.

• Manufactured and repaired tooling spares using lathe, milling, grinding and bench operations while ensuring dimensional precision.

• Coordinated with Production for mould changeovers, tool health monitoring, defect analysis, 5S implementation and safety compliance.