Mukund Raut

Spearheading Manufacturing Operations for Stepper Business Unit (add $ size of the business) with focus on lean and Industry 4.0 implementation

Production Management and lead WCM of the plant with ($ turnover of the plant)

Manufacturing

- Resource Planning and manufacturing KPI management.

- Goal deployment inline with the plant objective.

- Interdepartmental co-ordination with Maintenance, supply chain and New product development teams for effective project delivery, deployment of systems and breakdown management.

- OEE Analysis, identification of losses and development of\ counter measures.

WCM- (World Class Manufacturing)

- Lead -FI pillar of WCM in the plant.

- Achieved 3 score in FI and appreciated for Best project presentation and is benchmarked all over India.

- Project deployment and governance, Ergonomics Management, Safety and risk analysis, Quality Circle & Led cost saving projects through kaizen.

- Competency mapping and development.

- Responsible for Time Study & Line Balancing of Assembly Line.

- Drive SMED project to reduce set up loss within plant .

• Production Management and assembly line set up of 16 lines.
• Established the production level of DV6C model from 380 per day per line to 590 per day per line.
• Employee output enhancement 16 TC/person to 30 Turbo/Person with DMAIC approach and SCS, line balancing, Work content distribution and improving the Ergonomics.
• Implementation of the “Lean Production techniques” on the shop floor like MHS System for Material Handling, One piece flow, SMED, Set up time reductions. Etc.
• Worked on a project of “MRO inventory cost reduction”
• Driving the Opex projects like rejection cost, consumables cost to reduce the Conversion cost.
• Achieved cost savings of $ 200424.00 in consumables cost in 2011 and awarded with the India China Excellence Award in CY 2011.
• Reduced internal rework from 13000PPM to 5700PPM through the approach of 7 QC Tools.
• Defined Roles and responsibilities of the team members to deploy Standard Work .
• Drive the 5”S”, Kaizen, “Zero defect” and “Zero accident” culture on the shop-floor.
• Deployed the HOS practices on the shop to achieve the Silver Certification.
• Productivity improvement project by flexing operations aligned to customer demand with a target of 100% improvement in Productivity, Successfully achieved 50% improvement till.(tbd)

Key Role: NPI lead production.

• Led the NPI activities from the production side.
• Key role in developing and executing the work schedule for the PFMEA, DFMEA, Product Homologation, ODT, PPAP , Control Plan and SBR activities.
• Working with a CFT for flawless launches and could complete16 new launches in 2013 and 5 in 2014.

Projects Undertaken:

• New Gasoline Technology Turbo Charger introduced for Petrol Engine. It was the first gasoline project in India.
• Ford DV5 new launches
• VarOH- Operating Supplies-Production Cost Reduction
• TQC ( Touch for Quality check) implementation for Visual Inspection
• Drive Kaizen culture
• SMED (Set up time reduction)
• WIP reduction and Lean production practices on the assembly line Implementation of BEST practices of Europe in the plant.

Achievements

• Nominated for training in Europe for 3 weeks for understanding the best practices and implementation of the same at the plant.
• Six Sigma Green Belt Certified ( Set up time reduced by 60% though six sigma and consumable cost reduction)
• Awarded with Bravo awards for
• 1) successful Implementation of Material Handling System.
• 2) Installation of Kardex Unit for storing all tooling to utilize vertical height based on Lean concept.
• Installation of in-house Milling machine for reducing rework outsource cost. Total annual savings were $ 77419.
• Rewarded by INDIA-CHINA Excellence Award for saving of consumable cost by $ 200424.00.
• Won Outstanding performance in top 3 in QCFI .
• Twice Won the “Excellent” award in Quality Circle Forum of India National level in 2009 and 2011
• Appreciated for FI Pillar that gained 3 Score and was benchmarked by other plants in India for 2016 audit.

Responsible for Production activities and Engine Audit Room

Familiar with Engine assembly process, Expert in Valve setting, Engine Testing & Assembly Lines.

• Systematic problem analysis and counter measures,rejection control, product improvement, engine audit and testing.
• Approach on analysis & inspection on field failure.
• Documentation & Audit Management- ISO & QS
• Member of Continuous improvement team.
• Ownership of SQDIP