NAJIM A SHAIKH
Aurangabad,MH
Summary
Highly accomplished Lean Six Sigma Green Belt certified professional with over 21 years of expertise in production management, quality control, and customer relations within leading engine and genset manufacturing companies in India. Strong command of management techniques, including Kaizen, 5S, MOST, ISO standards, and Poka-yoke, combined with a deep understanding of Lean Manufacturing and A3 problem-solving methodologies. Recognized for exceptional leadership and communication skills that cultivate cohesive teams to achieve extraordinary business goals while emphasizing cost reduction and operational efficiency. Proven ability to build and maintain relationships with diverse stakeholders in dynamic environments, consistently delivering impactful solutions that enhance organizational performance and foster an engaged, empowering work culture.
Overview
21
21
years of professional experience
1
1
Certificate
Work History
Manager – Manufacturing Operation, Plant QA & Customer QA
Rehlko Energy India Pvt.Ltd
10.2020 - Current
- Manage all Plant quality and customer quality activity for diesel engines ranging from 2.5kw to 19 kw.
- Extensively working with the Global customer for the resolution of customer issue's with collaboration of service team.
- Managing oversees customer and weekly coordination with the customer to enhance customer satisfaction and delight the customer.
- Driving Problem solving methodology for the engine and Gensets business with the team by using the, DMAIC. A3, 8D.
- Reduce zero hours customer complaint from 4587 PPM to 1205 PPM
- FPY increase from 89% to 95.47% by reducing the defect rate through problem solving with collaborative approach
- Spearheaded the E2E operations of manufacturing diesel Engines from 4.5kw to 19 kw and Generators from 5 to 1010 KVA, Portable and Industrial compact and reliable generators for Indian & International Markets.
- Provided leadership for the E2E Plant Operation in Aurangabad facility for Engine & Generator manufacturing plant including dealer network in Aurangabad region to assist and boost sales activities.
- Managed all the manufacturing activities for Genset ranging from 3.2kw to 18.5 Kw & 3.5 KVA to 1010 KVA and Engine and handled the manufacturing expansion projects for 1250 to 2250 KVA, including the market study, benchmarking to proto BOM for initial approvals.
- Held responsible for the manufacturing plant process like assembly, testing, packing, Quality.
- Managed the operating & capital budget, monitored the monthly financial statements and submitted all the key reports to management to the Indian & Global Teams.
- Developed and implemented key policies, goals & objectives, manufacturing performance metrics, and improvements in-process controls, efficiency, labour utilization, and quality assurance.
- Determined and enforced, through functional groups, productivity, quality, and safety requirements in accordance with company needs, aligned with current regulations and state-of-the-art manufacturing processes.
- Developed and implemented plans for plant capacity additions ensuring the growth targets were met successfully.
- Experienced in Genset manufacturing facility improvement activities in reducing TPT and improving process and product quality.
- Handled the Supplier and Customer quality issues with the Head of Department, involved in the pricing activities and concerns for damage-free deliveries of raw materials.
- Worked closely with the Application team for product & cost improvement projects & the Head of Department to improve plant facility.
- Implemented and monitored all the tooling, process, and environment as per safety standards defined by the top management.
- Led daily meetings with the Cross functional teams for a smooth transition between shifts & processes of parts management, assembly, testing & dispatching.
- Conducted risk assessment of all plant processes and sub-processes to spot and reduce product failures and market complaints.
- Designed and led the project of the manufacturing processes in supporting business strategies to adapt to the changing market conditions, new business opportunities, and cost reduction strategies.
- Liaised with relevant support functions (Warehouse/ Maintenance / EHS/ HR) to troubleshoot operational issues as needed to achieve the production targets.
- Internal Communication: For internal & partner use only.
- Maximized performance by monitoring daily activities and mentoring team members.
- Accomplished multiple tasks within established timeframes.
- Established positive and effective communication among unit staff and organization leadership, reducing miscommunications, and missed deadlines.
- Identified and resolved unauthorized, unsafe, or ineffective practices.
Deputy Manager – Manufacturing, Plant QA, CQA
Kohler Power India Pvt Ltd (Generator Division)
04.2016 - 10.2020
- Served as Deputy Manager for Production & Client Relations with a specialized solution provider in Power Industrial & Telecom Sector.
- Leading the activity of type approval, CoP testing of Engine and Gensets, certification from ARAI.
- Coordinating with various departments such as Supplier Quality, vendor quality assurance for solving problem at customer, line “0” Km and “0” Hr. rejection related to the quality of the product.
- Worked on layout preparation of plant-to-plant build, planned the Manufacturing plant set up as per volume, Workforce recruitment, Training on the product, and the actual completion of the project.
- Coordinating EHS (Environment, Health & Safety) activities such as Near-miss / accident reporting, Mock drills, PPE’s adherence, investigation of accidents, HIRA, etc. for Mfg. & QA team.
- Coordination with Unionized Manpower for various issues / concerns.
- Negotiation and discussion Team member of management team for Wage agreement with union Leaders and Team Members.
- Clearly define the roles and responsibilities of team members and ensure enhancement of their skills and knowledge in the commodity for analysis of concerns, resolution of concerns, conducting audits, monitoring for improvement actions.
- Support to New Product Development (NPD) Process for all Genset models launched in India.
- Guiding the team Genset Manufacturing, Testing, Validation & Inspection of Gensets as per ISO 8528, NEMA MG1, Improve performance of Operation team through system discipline and motivation to Team Members.
- Ensure enhancement of competencies of team members through training, counseling, guiding, projects, etc.
- Internal Communication: For internal & partner use only.
- Liaised with team members, stakeholders and vendors to coordinate activities, provisioning, environment setup, risk mitigation and follow-up.
Assistant Manager – Customer Quality, Manufacturing Quality
Kohler Power India Pvt Ltd (Generator Division)
04.2013 - 03.2016
- Installed and designed state of the Art Genset test facility and sound pad for statutory approvals for Gensets for sound and emissions certifications. Responsible for Quality Assurance which includes – MOA & COA Daily, Weekly, Monthly targets, IMS, Cost reductions, Quality improvements etc.
- Handling Customer Inspection Testing from 3.5KVA to 650KVA genset.
- Support to New Product Development (NPD) Process for all Genset models launched in India.
- Centrally coordinating Kaizen & 5S drive for both units. Doing 5S audits & awarding awards for best division in 5S category & also for best top 5 Kaizens.
- Documented and executed SOP (Standard Operation Procedure), trained, and communicated with contract manufacturing personnel.
- Provided leadership including goal setting, improvement targets for KPIs, and performance management for continuous skill improvement of employees.
- Implemented the definition, introduction, and suitability of the quality management that assures the introduction of the quality policy and the achievement of quality goals.
- Reviewed the findings and assigned responsibilities for correcting deficiencies noted in audits, tracking all audit deviations and corrective action plans for timeliness to review and comment
- Devised and managed physical inventory audit methodology which meets corporate, governmental, and customer specifications; coordinated with central corporate Supply Chain to provide data and participate in teams to drive best practices within the company.
- Managed material cost, schedule impact of proposed engineering changes, and took necessary actions to ensure successful implementation and incorporation of approved releases.
- Maintained the FIFO & Production activities, loaded FG as per the plan, and tracked on a daily basis.
- Initiated a cost optimization activity to benchmark the product and enhance features to gain market.
- Gained Cost optimization in contractual workforce cost by various strategies to reduce indirect manufacturing costs.
- Provided solutions for assembly defects and was involved in various Quality improvement activities
- Internal Communication: For internal & partner use only.
- Offered hands-on assistance to customers, assessing needs, and maintaining current knowledge of consumer preferences.
Senior Engineer – Customer Quality
Kohler Power India Pvt Ltd (Generator Division)
06.2012 - 03.2013
- Analyzed and interpreted customer requirements to develop engineering solutions.
- Determined equipment failure root cause and implemented solutions.
- Responded to customer requests for products, services, and company information.
- Followed-through on all critical inter-departmental escalations to increase customer retention rates.
Engineer - Production
Kohler Power India Pvt Ltd (Generator Division)
04.2010 - 05.2012
- Developed positive working relationships with stakeholders to effectively coordinate work activities.
- Participated in formal internal design reviews of proposed products and components.
- Provided input to team lead regarding areas for process and procedural improvement.
- Collaborated with other departments to facilitate successful project completion.
- Developed and maintained relationships with suppliers to facilitate quality and timely delivery of materials.
- Trained and mentored junior engineers, providing guidance and direction.
Asst. Engineer - Production
Kohler Power India Pvt Ltd (Generator Division)
10.2006 - 03.2010
- Provided technical assistance to staff when needed.
- Assisted in development, design and execution of projects.
- Manage over 22 Working associate for the production.
- Planning daily activity to meed the production target.
- Review and analyses production losses and take necessary step along with other department to reduce the losses and improve productivity.
Trainee Engineer - Production
Kohler Power India Pvt Ltd (Generator Division)
09.2004 - 09.2006
- Hands on training on engines and gensets assembly
- Seek learning from senior to improve professionally.
- Learn ENgine and gensets working functions from the seniors.
Education
Batchelors of Engineering - Mechanical Engineering
Government Engineering College
Aurangabad, India12-2012
Diploma - Mechanical Engineering
Government Polytechnic
Aurangabad06-2004
Skills
- Production Management
- Lean Six Sigma Green Belt
- Project Management
- Budgeting & Costing
- Quality Control & Quality Assurance
- Audit Control Management
- Customer Relationship
- Operations Management
- Contract/Third Party Management
- Internal Auditor -ISO 9001, 14001
- Quality Management
- A3 Problem solving
- Thought Leadership
- Analytical & Strategic Thinking
- Innovation & Creativity
- Team Development & People Skills
- Collaborative Skills
- Interpersonal skills
- Conflict Resolution
- Cross-functional team management
- Shift scheduling
- Time management
- Customer service
- Goal setting
- Task delegation
- Resource allocation
- Team leadership
- Operations management
- Cross-functional teamwork
- Performance evaluations
- Performance management
- Staff training and development
- Decision-making
- Trend analysis
- Complex Problem-solving
Certification
- Six Sigma, TUV - [2023]
- MOST
- ISO 9001-2015
Work Availability
monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
swipe to browse
Timeline
Manager – Manufacturing Operation, Plant QA & Customer QA
Rehlko Energy India Pvt.Ltd
10.2020 - Current
Deputy Manager – Manufacturing, Plant QA, CQA
Kohler Power India Pvt Ltd (Generator Division)
04.2016 - 10.2020
Assistant Manager – Customer Quality, Manufacturing Quality
Kohler Power India Pvt Ltd (Generator Division)
04.2013 - 03.2016
Senior Engineer – Customer Quality
Kohler Power India Pvt Ltd (Generator Division)
06.2012 - 03.2013
Engineer - Production
Kohler Power India Pvt Ltd (Generator Division)
04.2010 - 05.2012
Asst. Engineer - Production
Kohler Power India Pvt Ltd (Generator Division)
10.2006 - 03.2010
Trainee Engineer - Production
Kohler Power India Pvt Ltd (Generator Division)
09.2004 - 09.2006
Batchelors of Engineering - Mechanical Engineering
Government Engineering College
Diploma - Mechanical Engineering
Government Polytechnic