RAHUL DK
Advance Manufacturing Engineering
Gurugram
Summary
Dynamic production and manufacturing engineer with over 6 years of experience in the manufacturing industry, recognized for exceptional problem-solving and analytical skills, complemented by meticulous attention to detail. Extensive knowledge of manufacturing processes and a proven ability to develop efficient equipment and production lines have consistently driven improvements in operational performance. A track record of successfully planning and executing production schedules, resolving quality-related issues, and conducting audits has resulted in significant enhancements, including a 15% increase in line efficiency and an 11.6% reduction in manpower costs. Seeking a full-time role that offers professional challenges while leveraging strong interpersonal skills, effective time management, and innovative problem-solving capabilities to align technical solutions with business objectives.
Pursuing full-time role that presents professional challenges and leverages interpersonal skills, effective time management, and problem-solving expertise.
Overview
7
7
years of professional experience
2
2
Certifications
2
2
Languages
Work History
AME
BHARAT SEATS LTD. Maruti Joint Venture
2025.04 - Current
- Prepared RFQ and cost analysis for new product development.
- Developed budget for tooling capex and assets to support production.
- Designed process layouts for efficient workflow.
- Process micro mapping with manpower allocation and process CT.
- Customer interaction and audit for DP event till SOP.
- Created SOR for new machine procurement, ensuring alignment with project requirements.
- Conducted DAP for new assets, ensuring compliance.
- Tool and Poke Yoke manufacturing and design review.
- Executed preparation of CAR-V shifting documents, including specifications for YXA, YED carpet, and YED trim.
- Tooling Preparation and tool development.
- Facilitate HF Welding Machine setup and installation processes.
- Process development stage to streamline production handover.
- RM feasibility analysis and development.
- Project Coordination and Marketing Expense development Supported RFQ drafting.
- New Product BOM Development with design development.
- Customer Handling for new and existing project work.
- Examine and assess problems while formulating solutions that conserve money, time, and materials.
- Work instruction preparation.
- SWS preparation.
- Doing Real time study and cycle time & eliminate the Muda.
- Line balancing and Yamazumi chart preparation.
- New Line layout set and improve existing line layout Preview.
AME
Autoneum India Pvt Ltd
2024.05 - 2025.04
- Design and develop new systems, processes and equipment to ensure manufacturing is efficient and effective, increasing productivity by 25% in YXA, YED Hood, Cowl, 25 % in Motor Cover Encapsulation molding and assembly.
- Investigate and analyze problems and devise solutions that save money, time and materials.
- Work instruction preparation.
- Give the Training to SQPCH on a yearly basis with respective departments’ employees.
- SWS preparation.
- Doing Real time study and cycle time & eliminate the Muda.
- Line balancing and Yamazumi chart preparation.
- New Line layout set and improve existing line layout.
- SWS and SWCT preparation.
- PST tool knowledge.
- SMED knowledge achieved 33% die change over reduction.
- Jishuken activity knowledge drives in Dash inner part and YTB hood part and achieved desired results.
- Capacity Calculation, OEE calculation and generate report daily basis and review.
- Tool & Die Inspection.
- Cycle time, Takt Time, Lead time calculation and prepared future line plan.
- Value Stream Mapping knowledge and plotting.
- Involve in MSIL tech. review event.
- Capex raises responsibility.
- KPI Managements system and update monthly KPI.
- APS production system run and run line SPF.
- Before SOP Honda, Maruti audited Tool trial report and audit documents preparation.
- New Tool inspection and tool trial and develop parameter.
- Innovation for BNW cutting machine installed in plant.
- Innovation for shader for scrap reused concept
- Lead 5s Audit and conduct summary the after before closer in kaizen form.
- Manage budgets and ensure project deadlines are adequately met according to standards and requirements.
- Implement Kanban system.
- Implement Andon System in plant.
- Improvements: Improved line efficiency using Line Balancing study. Improved efficiency by 25% on Press machine – Press no -04, Press no- 02, Press no-03. Improved efficiency by 10% on Felt Line - Improved line efficiency by 10%. Assembly Line – 3US HOOD, 3US DASH, Motor Cover Encapsulation - 450 to 600 no’s per shift. Saved 5% manpower in the whole plant through real-time study and reduced Muda on the line. Felt line – rejection percentage 4% to 2 % reduction through duct modification improve felt stiffness and bounding quality.
Production Engineer
Production Engineer Supreme Group Pvt. Ltd.
2019.01 - 2024.05
- Maximized productivity on the job by developing and implementing innovative production processes for new and existing products.
- Set New carpet line layout and manpower mapping for YHB carpet project.
- Used lean manufacturing tool for reduce The RMC cost in high runner part save 2.14cr annually.
- Doing real time study and reduce Manpower in hole plant 36 no’s monthly.
- Cut production costs by 20 % in Runner models.
- Develop the YWD poke yoke checking fixture and develop the part inspection fixture equipment.
- Set line layout in new project and improve existing line layout.
- Identified and addressed all issues that arose in a quick and efficient manner to ensure minimal interruptions of work.
- Created engineering documentation for manufacturing processes, equipment specifications and change notices.
- Improvements: Improved line efficiency using Line Balancing study. Improved efficiency by 15% on Thermoforming Line – T/F -04, T/F 02, T/F 01. Improved efficiency by 10% on Thermosetting Line - 400 T New, 200 T. Improved efficiency by 10% on Assembly Line – YHB FFC, YHC FFC, YHB RR, YHC RR, RX FFC and RX RR. Saved 11.6% manpower in the whole plant through real-time study and reduced Muda on the line. Improved Power Factor. Run YHB FFC and YHC FFC carpet line 6 manpower to 3 manpower assembly and moulding.
Education
B. Tech/B.E. - Mechanical
Mangalam School of Management & Technology
2022-01
12th - Diploma, English
2017-01
10th - Haryana, Hindi
2014-01
Skills
Operational efficiency enhancement
SPM Developement
Quality assurance proficiency
Safety program coordination
Value stream mapping
Pattern Production
PPAP documentation preparation
Process failure mode and effects analysis
Tool inspiration and evaluation
Toyota production methodology
SOR documentation preparation
DAP Preparation
CAR-V Documentation
DOJO 40
Vision Inspection 40
RFQ preparation
Budget management
Machine installation
Certification
Lean Six Sigma Yellow Belt
Timeline
AME
BHARAT SEATS LTD. Maruti Joint Venture
2025.04 - Current
VDA 6.5
2024-07
AME
Autoneum India Pvt Ltd
2024.05 - 2025.04
Lean Six Sigma Yellow Belt
2024-04
Production Engineer
Production Engineer Supreme Group Pvt. Ltd.
2019.01 - 2024.05
12th - Diploma, English
10th - Haryana, Hindi
B. Tech/B.E. - Mechanical
Mangalam School of Management & Technology