Prasad P G
Manufacturing Program Manager Sr. Staff
Aprameyah, Chamarajpet, Bangalore, Karnataka,KA
Summary
Experienced Project Manager with a demonstrated history of working in the networking industry 24 years of experience in Electronic Design and Manufacturing Industry (Juniper Networks, Flextronics and Motorola), in the areas of Operations Project Management, New Product Introduction, DFM/DFA, Product Life Cycle Process (PLCP), Quality Management, Root Cause Analysis, Continuous Improvement, and Kaizen.
Overview
25
25
years of professional experience
5
5
years of post-secondary education
Work History
Manufacturing Operations Program Manager Staff – NPI
Juniper Networks India Private Limited
10.2013 - Current
- Manufacturing operations lead to product NPI team, provide manufacturing plan (schedule) working with cross functional team (HW, SW & Systest) and assuring manufacturing readiness meets project launch timeline
- Manage manufacturing team for New Product Introductions (NPI) and ensure that product development deliverables are concluded for each phase and post-launch product changes
- For CM define proto schedule’s and conduct regular meetings with CM & NPI mfg
- Team to ensure the proto schedule timeliness agreed are executed as per the NPI timelines
- Work with materials manager to production COGS (cost of goods sold) for the NPI team and also ensure the materials are lined up for proto & Pilot builds
- Review and finalize budget required from operations to support proto/pilot builds and provide the same product NPI team
- Work with test engineering team to ensure the manufacturing test deliverables such as script development, regression test, mfg
- Diagnostics and diagnostics testing required for product testing is delivered to CM to meet the new product launch.
Sr. Manufacturing Engineer
Juniper Networks India Private Limited
Bangalore, Karnataka
11.2007 - 10.2013
- Working together with the Manufacturing Program Managers, conduct meetings with the Manufacturing partners, Manage the new product introduction (NPI) schedules, production readiness, factory capacity management and participate in product cost-reduction initiatives
- Represent value engineering team, recommend suggestions to the management regarding the Cost reductions, ROI, comparing the NRE investment to the savings to see if it even makes sense to pursue and also work towards implementing
- Work with Design Engineering team and ensuring that all necessary BOM, Drawings, specifications etc
- Are available prior to the build start
- Coordinate DFM/DFA (design-for-manufacturing/assembly) review of new designs and communicate the findings back to the design teams
- Ensure the manufacturing partners are actively engaged in the DFM process
- Identify and drive product and manufacturing process cost improvement opportunities for overall cost reduction
- Conducts Proto/Pilot Readiness review with CMs, includes process flow, proto capacity, equipment capability evaluation, reviews document package for data integrity and special instructions prior to each proto, etc
- Provides feedback to CMs on proto build performance and process problems at Juniper
- Working with Mechanical designer at early design stage to review mechanical design, provide DFA feedback, identify nonvalue added activity, cost reduction opportunity, tooling requirement (Hard tool v/s soft tool), ROA review for tooling, Hard tooling qualification on site, FAI sample review and approve the design
- Identify technologies required for new products, evaluate, and qualify Contract Manufacturers for those technologies
- Represent Contract Manufacturers at Juniper sustaining meetings, communicate Juniper quality issues to Contract Manufacturers and drive corrective action and yield improvement plans to achieve Juniper's goals
- Manages engineering changes at CMs during proto builds (via ECO and Deviations) and qualification of PCB’s interacting with Sustaining Engg team, CM and FAB vendors
- Responsible for preparing destructive analysis mapping for new products and coordinate with contract manufacturers to perform destructive analysis, review the report and approve.
Engineer
Flextronics / Motorola
06.1997 - 11.2007
- Facilitating and coordinating the entire NPI activities from design to mass production by interfacing with customer and ensure requirements to build the product are met
- Key responsibility in coordinating with Design team in implementing DFM / DFA for PCBA and Mechanical assembly
- Review of engineering documentation (design deliverables), Coordinate the process engineering department activities in setting up & implementing manufacturing process for the products manufactured
- Work on the continuous improvement of the process to achieve the quality, cycle time and cost reduction goals and with customer care team in closure of corrective and preventive actions for the customer complaints
- Analysis of process failures using statistical approach and implement short term and long-term corrective action
- Schedule and lead brainstorm sessions, design reviews, FMEA and management reviews
- Implementation of SPC tools for the introduction of new projects
- Review all the customer documents related to Bill of Materials, AML, Assembly drawing, manufacturing specifications, test procedure, ECO/Deviations, and special instructions along with the respective team for data adequacy for running the product
- Lead the team of Engineers & Technicians to achieve the organization goals, Track performance of technicians and work towards continually improvement of their performance
- Major Achievements:
- As in Program Manager role successful launch of 15 products across Routing, Security and Switching by working with cross functional NPI team
- Effectively handled new product introduction process set up for more than 100 PCBA & around 10 variants of system assembly used in telecom networking, set up boxes and point of sales assembly
- Onsite support during Pilot run and successful launch of products by effectively solving pilot issues by interacting with CMs, Engineering team
- Till date have supported more than 20 products launch
- Certified Six Sigma Green Belt Certification from Flextronics Corporate and have completed 2 six sigma projects
- (Packaging Material Cost Reduction and DPMO reduction)
- Supported PCB commodity team to reduce FAB cost by qualifying alternate laminate for various products
- Savings achieved more than $ 200k/year
- Key responsible person for Certification of LEAD FREE SMT & WAVE SOLDERING Process for Flextronics Bangalore Facility
- Responding to Customer requirements in a short lead-time and effective implementation of the changes in the line to meet the customer requirements
Education
Post Graduate Diploma - Operations Management
Symbiosis University
Pune 06.2009 - 05.2011
Diploma - Mechanical Engineering
PES Polytechnic
Bangalore 06.1991 - 05.1994
Skills
Manufacturing operations
Manufacturing activities planning
Accomplishments
- As in Program Manager role successful launch of more than 30 products across Routing, Security and Switching by working with cross functional NPI team
- Effectively handled new product introduction process set up for more than 100 PCBA & around 10 variants of system assembly used in telecom networking, set up boxes and point of sales assembly.
- Onsite support during Pilot run and successful launch of products by effectively solving pilot issues by interacting with CMs, Engineering team. Till date have supported more than 20 products launch.
- Certified Six Sigma Green Belt Certification from Flextronics Corporate and have completed 2 six sigma projects. (Packaging Material Cost Reduction and DPMO reduction).
- Supported PCB commodity team to reduce FAB cost by qualifying alternate laminate for various products. Savings achieved more than $ 200k/year.
- Key responsible person for Certification of LEAD FREE SMT & WAVE SOLDERING Process for Flextronics Bangalore Facility.
- Responding to Customer requirements in a short lead-time and effective implementation of the changes in the line to meet the customer requirements
Timeline
Manufacturing Operations Program Manager Staff – NPI
Juniper Networks India Private Limited
10.2013 - Current
Post Graduate Diploma - Operations Management
Symbiosis University
06.2009 - 05.2011
Sr. Manufacturing Engineer
Juniper Networks India Private Limited
11.2007 - 10.2013
Engineer
Flextronics / Motorola
06.1997 - 11.2007
Diploma - Mechanical Engineering
PES Polytechnic
06.1991 - 05.1994