Rakesh Kumar
Sarkaghat
Summary
Manufacturing Engineer with 14+ years of hands-on shop floor experience in automotive manufacturing. Strong expertise in process setup, cycle time optimization, line balancing, and productivity improvement. Skilled in RCA (8D, 5-Why), defect reduction, PPAP support, and quality-at-source implementation. Proficient in 5S, Kaizen, Poka-Yoke, TPM, and lean manufacturing tools.
Overview
15
15
years of professional experience
Work History
Assistant Manager - Production
Gabriel India Ltd.
Parwanoo
09.2010 - Current
- Handled 200+ shop floor operators across shifts, including shift planning, manpower allocation, line balancing, and attendance discipline to meet daily production targets.
- Drove daily production as per PPC plan, monitored hourly output, downtime, and shortages, ensuring smooth material flow in coordination with Stores.
- Monitored rejections and containment using red & yellow bin system, performed daily defect analysis, and implemented immediate corrective actions on the line.
- Maintained shop floor discipline, 5S, FIFO, and standard work, ensuring proper identification and segregation across production lines.
- Led root cause analysis using Why-Why, Pareto, Fishbone, and 7 QC tools, implemented CAPA, and verified effectiveness through follow-up checks.
- Supported quality control activities including first-piece approval, in-process inspections, and CTQ/CTS/CTC awareness, ensuring compliance with IATF 16949 requirements.
- Implemented and maintained IATF 16949 documentation, such as SOPs, Work Instructions, Control Plans, check sheets, and audit records; trained operators, and supported internal/external audits.
- Performed tool inspection, basic troubleshooting, and minor tool corrections in line with IATF 16949 tooling control requirements, reducing tool-related breakdowns and quality issues.
- Actively involved in tool modification, improvement activities, and preventive maintenance documentation to improve tool life, reduce rejection, and enhance productivity.
- Maintained tool history records, condition monitoring, PM schedules, and supported new tool trials, process validation, and first-off approvals as per IATF 16949 standards, contributing to cycle time and changeover reduct
- Production
- Tooling
Education
B.Tech. - Mechanical Engineering
Karnataka Open University
01.2014
Diploma - Mechanical Engineering
PIET
HR01.2010
Secondary Education -
HPBOSE
01.2004
Skills
- Production planning
- Root cause analysis
- IATF 16949 compliance
- GD&T
- CAD: AutoCAD
- Manpower management
- Tool maintenance
- Kaizen, Lean Manufacturing & 5S
Trainings Attended
- CST (Creative skill training)
- TLDP: - Specially designed training for Team leader by Anand U.
- ASTEP: - Advanced training for Supervisor by Anand U.
- STAR: - Supervisor Training for action and results.
- Fire Fighter, First Aid & Rescue.
Languages
- English
- Punjabi
- Hindi
Timeline
Assistant Manager - Production
Gabriel India Ltd.
09.2010 - Current
B.Tech. - Mechanical Engineering
Karnataka Open University
Diploma - Mechanical Engineering
PIET
Secondary Education -
HPBOSE