Sachin Padalkar
Aurangabad
Summary
Aspire to pursue senior management position with a progressive organization to be a part of its growth COMPETENCY New Product Development Project Management TPM Lean Manufacturing Client Relationship Management Team Management Vendor Development Configuration Management OVERVIEW Achievement-oriented professional with over 25 years of experience in New Product Development,Manufacturing Process and Lean Manufacturing Proficient in suggesting & implementing required changes in process as well as technology to improve product quality& reducing Cost Honed with a sound process knowledge of Hot Forging, Pressure Die Casting, Machining, SPM, Painting, Plating, sheet metal working, Reverse Engineering Conversant with concepts of AS 9100 / EN 9100, TS-16949, ISO 9001, QS 9000, 8D, CAPA, PPAP, FMEA, APQP, SPC and 7 QC Tools. Well versed with Six Sigma, Lean, Pokayoke Kaizen, DOE, Project Management tool At Task An effective communicator with good analytical, interpersonal and problem solving skills
Overview
31
31
years of professional experience
Work History
Head
MAHINDRA DEFENCE NAVAL, MDNS, BEKAERT INDIA LTD.
•GREAVES COTTON LTD.
•CANPACK INDIA LTD.
•LARCEN & TOUBRO DEFENCE
•PERKINS INDIA LTD, BAJAJ AUTO LTD, MAHINDRA DEFENCE
- Design, Manufacturing, Delivery of custom made designs with VA concepts
- Designed & executed Exhaust gas cleaning Scrubbers(EGCS) for exhaust from marine engines as per IMO norms
- Responsibility right from conceiving of entire product, validation from customer, selection of a number of parameters as selection of materials, manufacturing processes , assembly and tryout
- A number of varients of EGCS were designed ranging from 7MW to 25 MW
- Process Design & input was under the customer command
- Mentoring & monitoring entire manufacturing at overseas fabricators end was one of the important tasks
- Preparing 3d models & manufacturing drawings to enable ease of manufacturing was done successfully
- Adhering to PQCDM with low lead time was a prime target
- Achievements
- Headed team of 15 members from conception to delivery of design details was achieved in span of 4 months
- Specialization
- Delivery of complete package for manufacturing without rework & redesign
- Lowest response time(Quick delivery)
- Design for manufacturability & assembly made successful assembly possible witin a time span of 21 days
- 3d models & 2d drawings as per international standards, An outstanding contribution in the area of development of IMPORT Substitutes which was one of the pain areas of our customers
- Thereby resulting in considerable reduction in Project cost and lead time
- Ability to work hard on cost reduction and reduction of lead time awarded us a number difficult to achieve projects from our esteemed customers
- Headed a team of designers working in areas for
- Heavy Fabrication Fixtures
- Automotive BIW Chassis Weld Line Fixtures
- Sheet Metal BIW Weld Line Fixtures
- Weld Fixtures for Robotic and Manipulators
- Machining Fixtures
- Checking Fixtures and Gauges
- Press Tools
- Legacy Data Conversion to 3D and 2D
- 3D modelling and CNC tool path generation
- Cad Customization
- SPM’s
- Detailed Factory Layouts
- Complete Process Planning
Bajaj Auto Ltd
01.2000
- IsOne of the largest two and three wheeler manufacturing company providing competitive automobile products with indigenous design & manufacturing of motorcycle, three wheelers and now QUADRICYCLE also with a huge emphasis on manufacturing of genuine spare parts Company is certified with ISO 9001:, , 14001, with revenue in million Indian Rupees of 269,105.1 and total 4 facilities in India.
Plant Head
Yeshwant Industries Aurangabad
11.2020 - Current
- Working at Yeshshree Group of companies as DGM(ME) was a crucial role in managing an entire Robotic welding line consisting of 50 Fanuc robots integrating with weld fixtures
- Ability of Process analysis,designing & execution were major contributors of a great success
- Heading Yeshwant industries with expertise in areas of machine tool design & manufacturing is an additional responsibility
- A number of overseas dispatches with RFT has opened new avenues of business for Yeshwant Industries
- The journey continues till date.
Dy. General Manager
Yeshshree Press Comps. Pvt. Ltd
Aurangabad
10.2019 - 11.2020
- Reviewed performance results to target and take corrective measures with authorization and escalation.
- Fostered and promoted cooperative and harmonious working climate conducive to maximum employee morale, productivity and effectiveness.
- Prepared annual budgets with controls to prevent overages.
- Drove year-over-year business growth while leading operations, strategic vision and long-range planning.
- Employed best practices and management controls to provide superior service to internal and external customers.
- Maintained qualified staff and communicated areas of accountability and expected performance.
- Applied creative reasoning and logic to resolve complex and specialized managerial issues and develop sound solutions.
Project Manager
Expert Global Solutions Pvt. Ltd
Aurangabad
11.2018 - 08.2019
- Responsible for conceiving customer project requirement,analyze the technical details. Project was to design a gas scrubber ,manufacture, Tryout & install at overseas customer
- Met project deadlines without sacrificing build quality or workplace safety.
- Maintained clear communication with precise technical writing to document and inform critical processes.
- Facilitated communication between internal personnel, contractors and vendors for project cohesion.
- Updated operational methods and oversaw accounting procedures for improved efficiency.
- Developed and initiated projects, managed costs and monitored performance.
- Maintained relationships with material vendors to lower costs and diversify capabilities.
- Planned, designed and scheduled phases for large projects.
Operations Head
Success Solutions
Aurangabad
09.2010 - 10.2018
- Head Of Design,Manufacturing, Delivery of custom made engineering Goods to a number of MNC’s
- Designed and executed a project of KEMPEL and INDIAN NAVY project turbo charger breather.Program code: -MAN 4 STROKE MSE (101116).Here base idea was to rebuild fabricated breather in place of castings
- We did redesign of fabricated structures and complete machining of the same
- This was a process change for reduction of lead time and cost
- This was done with team of MES from Denmark
- Exported machined and fabricated parts of diesel generator sets to MES - SAINT NAZZAIRE for MANA
- Manufacturing of Rammer Chain for WAR TANKS for MDNS was another feather in our cap
- Not so easy to achieve task was completed with complete customer satisfaction AWADI
- Program code: -Rammer chain (49-00-00-00-000)
- Task was to carry out precise machining, heat treatment, grinding and assembly to form a rammer chain
- Also mechanism to inspect rammer chain was designed and manufactured as per customer demand
- Rework and installation of cover for turbocharger for MES & BHEL (Bhopal) was one of our outstanding achievements
- Program code :- STATOR_ASSLY_PART( BHEL_STPL_098725)In this project we had to design,get approval and DAP from BHEL, fabricate, machine and assemble it on MAN engine(1033345)
- Connecting rods for 28/32, TC Footfor 27/38, Dip sticks for entire range of diesel engines
- Program code: -AADISHAKTI TC foot (2182136-0)it was very critical project, wherein slightest deviation on surface would result in heavy oil leakage, machining and finish grinding demanded tight control
- Manufacturing of spacing rings for BEKAERT to be used in wire drawing machine head with air bearings was a tough task
- Accuracy required was 2 microns surface parallelism
- Project code:- 0000254894
- Manufacturing of Cylinder Head for electronic engine for Perkins India ltd
- Was a difficult task which we did with perfection.Project code: - Perkins Head Cylinder 8001000149
- Cylinder head valve bore was having deviation than specified in manufacturing drawing
- We did machine a pilot batch of 61 heads to the accuracy demanded by customer
- Manufacturing of machine elements for CANPACK along with gauging devices for aluminium cans was done successfully
- Consumables of over size 75 series dip sticks for APE and PIEGIO as fully packaged dispatch for Greaves Cotton was an assignment for direct consumer market all over INDIA.Project code: - 1900500013
- Role was to manufacture rubber moulded steel dipsticks with chemical bond to withstand temperature of 125 degrees
- Independent Handling of Customer Product study, Design& Manufacturing, getting approval from customers wrt
- DAP , Layouts ,Material specifications, AFAM, Testing of pilot batch material specifications
- Technical expertise in process Planning, Responsible for Design for Ease of manufacturing and ease of assembly, Project monitoring till manufacturing process is stabilised
- Headed teams in PROJECTS DEPT
- At implementation stage for process proving.Responsible for improving overall equipment efficiency
- (OEE)
- Excellent hands on expertise on a number of manufacturing processes which includes machining, heavyFabrication , design of non standard manufacturing processes needed by customers
- Achievements
- Headed the team at Success Solutions to grow it initially & to reach a turnover of 1.5 crores in 18 months with initial single customer to 12 industrial giants
- Cost of Operations brought to lower level by 7%
- Implementation of value addition projects by VE concepts thereby reducing product cost by 3%
- Improvement in OEE resulted reduction of maintenance cost by 10%
- Specialization
- Conceptualization of customer design& manufacturing needs
- Providing Technical guidance with ref
- To change of existing manufacturing process to a better one which will reduce project lead time
- Expert in handling of difficult to manage projects which would otherwise need more time and cost
- Catered to variety of customers from consumer goods manufacturers to defence supply organisations with the concept of“Make in India” conceptas:-
- MAN ENERGY, (INDIA & FRANCE)- MES
Tool Design Manager
Bajaj Auto Ltd
Aurangabad
08.1991 - 08.2010
Education
Master of Business Administration (MBA) - Marketing
Marathwada University
1996
Bachelor of Engineering (B.E - ProductionEngineering
Walchand Institute of Technology(Shivaji University)
1991
Skills
- Head of Tool engineering dept At BAL (Bajaj Auto Limited) Successfully delivered several new 2 Wheeler and 3 Wheeler vehicle programs
- Head of procurement at Yeshshree press components
- Responsible for procurement of robotic welding line project worth Rs 50 crores including indigenous & import items
- Responsible for process improvement strategies, cost reduction, productivity improvement, contract management , systems building
- Expert in team building & planning
- Project analysis, planning, negotiations with the suppliers, cost analysis, technical & commercial validation of SCM process
- Person with unsurpassed work ethic with procedure development
- Head of Core team members for execution of management projects on new projects Responsible for developing product development strategies in close association with the quality parameters
- Responsible as team head for ensuring timely execution of project as per agreed timeline with customer by conducting reviews with all CFT members
- Coordinator of teams working in close coordination with work groups for guidance in process development, detailing on quality requirements and finalizing the quality plan
- Highlights:
- Efficiently & successfully managed new products development for products of motorcycle and three wheeler Headed a team for completion of one of the cost saving and change over manufacturing process project for Petrol Tank for two wheeler
- Had been a Key contributor for Kawasaki 4 stroke Motorcycle development, CALIBER Motorcycle, ELIMINATOR Project code: - DJ141001 Main focus was to develop crankcase and related tooling
- Head of Product & Manufacturing Process conceptualization Responsible for: Managing internal customers from all 4 plants spread all over India Headed team of Engineers including Quality Eng, Manufacturing Eng, Product Eng, Tooling Eng, Planner, Buyer
- Create an environment that is culturally embedded in a "Quality First" mentality Ensure all levels of the organization are focused on providing the customer with defect free product
- Execution of use of number of projects using advanced software such as UNIGRAPHICS, Simulation software for project management
- Paid a significant contribution in establishing Product Development Procedure to enhance the process of PPAP & customer approval-Sigma
- As Head of TE, Visited various customer sites in India to understand Product functionality, Technical Discussion & implied needs during the development stage
- As a part of MBO, conducted and implemented a project of the most value addition in Redevelopment of press tool dies for three wheelers by Reverse Engineering
- Effectively worked as s team lead with vendors as TCS, DELCAM,and DRAN which contributed in development of 3d models using reverse engineering Vendor development forbought out parts & processes enhancement
- Team Lead of SAP implementation team which included study of manufacturing process, a number of report generation, effective development of user interface , legacy data storage and migration
- Executive committee member for Bridging GAP between SAP and end user by implementation of WRENCH :- a software developed for creation of data records in SAP
- Planning team head for Development of number of jigs , gauges, SPM’s and welding fixtures for 2 wheelers and 3 wheelers steel , sheet metal, and aluminium parts
- Expert in area of GD &T , well versed with engineering drawing reading and understanding
- Implemented a number of projects right from concept design, manufacturing along with Creation of 2d drawings suitable for manufacturing and 3d models for tool path generation
- Other important role was of lead in Development Management (TPM Pillar) and worked with world famous TPM Guru Prof Yamaguchi in overall development of manufacturing processes at Bajaj Auto Ltd
- Achievements
- Headed and successfully implemented project of Cost Reduction in “Four S” Petrol tank resulting in saving of Rs 12 crores per annum Project code :- AS142003
- This project won the Managing Directors Special Performance Award in year 2010
- Reduction in lead time and processing time of “3 wheeler Kubota” chassis by combination of products Project code: - AL312006this involved make and shift arrangements in existing fixture to accommodate new ones
- On single welding fixture there by saving of Rs 135 per chassis
- Implementation of value addition projects by VE concepts thereby reducing product cost by 7%In 3 WH CNG & LPG chassis,Project code :- AJ 23008
- Improvement in OEE resulted reduction of maintenance cost by 12%
- Specialization
- Conceptualization of customer welding fixtures designs using Robot
- Expertise in handling of combination of Products on common utilities there by reducing additional cost
- A special project for manufacturing of pressure die casting for RE 4S , Crank case for Caliber(Hudibaba) Eliminator, cylinder block for RTZ
- Designed a number press tool dies for main member of entire range or RE
- Expertise in the area of welding fixtures design for Platina, RE Petrol tank, CNG RE
- Rewarded for process improvement for assembly line for three wheeler RE
- Expert in reverse engineering of automobile productsProject for manufacturing of press tool dies for 3WH RE reinforcements was done by digitising of old dies for forming , bending ,trimming and converting , inspection of point clouds with DELCAM and TCS team within specified time period of plant shut down
- INDUSTRIAL TRAININGS
- A full one month training in
- UNIGRAPHICS NX at TCS Pune
- AS 9100, ISO 9001, QS 9000, TS 16949, MSA, FMEA, Statistical Process Control, APQP, PPAP, Lean Manufacturing and Design of Experiment, Six Sigma
- Six Sigma at Institute of Quality & Reliability
Accomplishments
- Chief Implementer in framework of quality standards and overseeing smooth implementation of the project
- Head of teams that refines concepts through client interactions including conference calls; responds to directional feedback from Core teams
- An effective expert in Development Management ( One of seven pillars of TPM), taking process enhancement initiatives like Kaizen, Lean & Six Sigma
- Hands-on experience in reviewing performance of vendors based on various criterions like percentage for rejections, quality improvement rate, vendor evaluation & rating system, etc.
Skills - Expert in design of all automotive manufacturing processes
Good working skill in -
1.Design software's as Autocad, Unigraphics-CAD and CAM
2. Manufacturing process planning & process validation
3. Heavy fabrication of industrial goods
4. Assembly & installations of equipments at customers site
5. VA/VE proposals
6. Infrastructure installations
Timeline
Plant Head
Yeshwant Industries Aurangabad
11.2020 - Current
Dy. General Manager
Yeshshree Press Comps. Pvt. Ltd
10.2019 - 11.2020
Project Manager
Expert Global Solutions Pvt. Ltd
11.2018 - 08.2019
Operations Head
Success Solutions
09.2010 - 10.2018
Bajaj Auto Ltd
01.2000
Tool Design Manager
Bajaj Auto Ltd
08.1991 - 08.2010
Head
MAHINDRA DEFENCE NAVAL, MDNS, BEKAERT INDIA LTD.
•GREAVES COTTON LTD.
•CANPACK INDIA LTD.
•LARCEN & TOUBRO DEFENCE
•PERKINS INDIA LTD, BAJAJ AUTO LTD, MAHINDRA DEFENCE
Master of Business Administration (MBA) - Marketing
Marathwada University
Bachelor of Engineering (B.E - ProductionEngineering
Walchand Institute of Technology(Shivaji University)