Rinku Kumar
Summary
Expert in Process Engineering and adept at leading teams, my strategic planning and Kaizen improvements significantly enhance operational efficiency and production capacity.
Skilled in leadership, operational strategy, and financial management. Excel at communication, problem-solving, and adaptability to drive team success and achieve organizational goals.
Overview
18
18
years of professional experience
Work History
Senior Manager – Manufacturing Engineering (BIW & Press)
Tata Motors
Pantnagar
05.2017 - Current
- Developed proposals and plans for major manufacturing facilities based on a 5-year strategy.
- Provided strategic planning inputs for short-term and long-term.
- Oversaw facility planning, layout planning, and logistic planning, including the installation and commissioning for both new and existing projects.
- Prepared an estimation sheet (Capex) for fixtures and dies, and facilitated the planning and procurement of weld line jigs and equipment based on technical specifications.
- Orchestrated the installation and commissioning of various weld line equipment, including robotic spot welding guns, cranes, scissor lifts, sealant machines, sliding platforms, manual guns, and CO2 machines.
- Attended DMU for new projects, analyzing body design in PLM and Catia to identify quality, productivity, and cost improvement points, resulting in a streamlined production process and cost savings.
- Conducted DFA/DFM for weld lines and dies, providing constructive feedback to ERC before finalizing designs for new products, leading to improved product quality, and reduced manufacturing costs.
- Demonstrated expertise in formalizing make vs. buy decisions and preparing business cases with payback analysis and risk assessments, contributing to informed decision-making and cost-effective procurement strategies.
- Planning and procurement of weld line jigs/equipment is based on responsibility for VC release as per Modular Architecture in BIW, and ensuring timely SOR and PO for the same.
- Lead planner for the planning and execution team for body shell welding of new models, viz.
Manager – Manufacturing Engineering (BIW & Press)
Tata Motors
Pantnagar
05.2012 - 05.2017
- Responsible for managing overall process engineering, involving new product development, proto development, process designing, facility planning, performing process analysis, and material flow management.
- Responsible for the implementation of BIW equipment, such as walking beam conveyors, skid conveyors, welding robots, robotic and manual spot welding guns, etc.
- Responsible for the implementation of engineering change management in sheet metal panels and assemblies, DFA, DFM, and design mock-up (DMU).
- Responsible for the implementation of advanced manufacturing engineering tools in existing and new projects: Kaizen, Lean Manufacturing, Takt time analysis and time study, man-machine utilization improvements, line balancing, SPC, and Poka-Yoke.
Assistant Manager – Manufacturing (BIW & Press)
Yamaha Motors India Pvt. Ltd.
Surajpur
05.2010 - 05.2012
- Conducted comprehensive manufacturing process studies of the weld line and press line, including the sequence of operations and tooling development.
- Collaborated with product development engineers to provide feedback on product design, enhancing the robustness of the manufacturing process.
- Prepared detailed process documents such as weld line process sheets, sealant plan, MIG weld plan, process flow diagram, PFMEA, and model identification sheets.
Led the tryout and development of press parts for fuel tanks and suspension items. - Ensured the validation of spot welding gun parameters, including nugget test and chisel test, contributing to the overall quality control process.
Assistant Manager – Manufacturing (BIW & Press)
SKH Metals Ltd
Gurgaon
05.2007 - 05.2010
- Managed production targets through efficient use of workforce, materials and equipment.
- Managed workforce and encouraged operators to achieve peak performance.
- Calculated Overall Equipment Effectiveness for performance monitoring.
- Generated cost savings in raw materials, indirect materials, spares, tooling, manpower.
- Managed comprehensive documentation of the press shop.
- Oversaw comprehensive auditing processes for ISO/TS-16949 compliance.
- Executed defect identification and correction through strategic analysis methods.
Education
Bachelor of Engineering - Mechanical Engineering
Shivaji University
Maharasthra03-2006
High School Diploma -
J&K Board
Jammu04-2001
Master of Technology - Artifical Intelligence & Machine Learning
Birla Institute of Technology
PilaniSkills
- Process Engineering
- Lean manufacturing
- Capacity Planning
- Facility Planning
- Green & Brown Field Projects
- Time study, line balancing
- Cycle study optimization
- BOM, cost release
- Process simulation tools
- Kaizen improvements
- Problem-solving
- Cycle time
Accomplishments
ACES Award from ED-CVBU for the installation of Magic Express by modifying the existing line without hampering the regular production
ACES award from ED-CVBU for ramp-up of production capacity of Magic Express to meet the market demand
ACES award from ED-CVBU for migration, installation, and PIST improvement of 85% for intra project
Awarded for outstanding contributions in the ordering and management of sheet metal dies for new projects
Major Achievements
- Successfully completed the Magic Express project within a 7-day timeline, including the rearrangement of 25 welding stations, installation of new spot welding guns, robotic stations, and setting up robotic hemming cells for side doors
- Increased weld shop production capacity for Magic Express from 30 to 80 units per shift, meeting the demand for 2,000 units
- Enhanced PIST efficiency from 65% to 85% for Magic Express and Intra models by modifying designs, and improving sub-assembly fixtures and main line processes
Languages
Kashmiri
First Language
Hindi
Advanced (C1)
C1
English
Advanced (C1)
C1
Personal Information
- Father's Name: Sh. Bakshi Lal
- Date of Birth: 12/09/83
- Gender: Male
- Nationality: Indian
- Marital Status: Married
- Religion: Hindu
Timeline
Senior Manager – Manufacturing Engineering (BIW & Press)
Tata Motors
05.2017 - Current
Manager – Manufacturing Engineering (BIW & Press)
Tata Motors
05.2012 - 05.2017
Assistant Manager – Manufacturing (BIW & Press)
Yamaha Motors India Pvt. Ltd.
05.2010 - 05.2012
Assistant Manager – Manufacturing (BIW & Press)
SKH Metals Ltd
05.2007 - 05.2010
Bachelor of Engineering - Mechanical Engineering
Shivaji University
High School Diploma -
J&K Board
Master of Technology - Artifical Intelligence & Machine Learning
Birla Institute of Technology
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