SONU KUMAR
Manager Manufacturing
Bhiwadi,RJ
Summary
An achievement-oriented professional offering over 12.5+ years of diversified experience and year-on-year success in directing the entire Production and Quality Operations focusing on top & bottom-line profitability by ensuring optimal utilization of resources. Successfully utilized qualitative & quantitative skills in increasing awareness by promoting and implementing various modern tools. Exhibited excellence in leading process improvement & cost reduction projects and implementing quality systems for enhancing production efficiency; enhanced the operational efficiency of workforce by focusing on technical & customer-oriented aspects. Talented Manager with expert team leadership, planning, and organizational skills built during successful career. Smoothly equip employees to independently handle daily functions and meet customer needs. Diligent trainer and mentor with exceptional management abilities and results-driven approach. Strong leader and problem-solver dedicated to streamlining operations to decrease costs and promote organizational efficiency. Uses independent decision-making skills and sound judgment to positively impact company success.
Overview
13
13
year of professional experience
2
2
SAP PP Certification
Work History
Manager - Production
Kaizen Metal Forming Pvt Ltd
10.2023 - Current
- Planning and Execution Production Schedule
- Ensure 100% Plan vs
- Actual Production Targets, Meeting Customer schedule
- Press shop capacity improvement 6 spm to 8 spm taking corrective actions
- Responsible for Continuous improvements in the production line
- Daily Analysis of Red Bin to find out the root cause and take necessary action accordingly Responsible to maintain good customer relation, taking corrective measures and increase productivity
- Implemented & sustenance of SFMS (Shop Floor Management System) Initiated by Top Management Responsible to increase productivity by JIDOKA Accountable for managing shift concerns and allotments, Weld shop, Press shop capacity improvement, Performance reviews
- Ensuring Products meet quality standards, inventory controls
- Ensure smooth flow of production in Assembly line throughout balancing WIP in shop floor
- Preparing and Sending Daily/Monthly MIS and CRM data to Management
- Achieving maximum OEE reducing rework and rejection, minimizing wastes
- Ensure that health and safety guidelines are followed all time
- Procurement of robots/equipment's based on technical specification and based on procurement procedure, good knowledge of Drawing Reading & Welding and Press machine and Press tools
- Manage working hours and shift schedules as per production targets & ensure optimum utilization of assigned man power
- Plant capacity calculation, takt time & cycle time study, plant layout improvements
- Ensuring Daily Production, 16 losses, Rework and Rejection Entry in SAP, making analysis of Rework & Rejection
- Preparing and planning team members KRA, leave plan, skill matrix & given training for multi skilling for smooth flow in department
- Cycle time study for line balancing and eliminating bottleneck Process
- Troubleshooting & Programming of welding robots of ABB, KUKA, and Panasonic & YASKAWA
- Knowledge of process validation & re validation
- To minimize tools setting time & improve productivity by training of operators
- Optimization man & machine utilization to achieve pre-set targets
- Developing new process concepts for production optimization
- Maintained production documents as per TS-16949, EMS & OHSAS18001 requirements Fixture correction & Improvements, implementation Poka yoke for reducing Costs
- Verify & Control on all types of wastage
- Verify TPM ,5s and kaizen implementation
- To monitor production, recording hourly performance in absolute details of part produced goods
- Preparing periodic reports and analyzing them like customer Rejection & in house rejection, productivity & welding cost, manpower cost etc
- Handling customer complaints and analysis them & taking corrective and preventive actions
- Maximized performance by monitoring daily activities and mentoring team members.
- Communicated clearly with employees, suppliers and stakeholders to keep everyone on same page and working toward established business goals.
- Achieved departmental goals by developing and executing strategic plans and performance metrics.
- Planned and budgeted accurately to provide business with resources needed to operate smoothly.
- Facilitated successful cross-functional collaborations for the completion of key projects, fostering strong working relationships among team members.
- Managed and motivated employees to be productive and engaged in work.
- Cost reduction initiates and implementation
- Estimating costs and preparing budgets
- Manage cost and time constraints.
Assistant Manager - Production
Belrise Industries Pvt Ltd
08.2017
- Handling a team of 350+ staffs and line associates (7 Frame body lines, Muffler line, swing arm, Brake Pedal, Link Engine Hanger, Handles, Side stand, Main Stand Assembly lines and Kubota Tractors assemblies)
- Prepare and arrange for tools and equipment required for the production, as per the defined production plan
- Check the readiness of the line by testing the equipment arranged by Technical Services
- Ensure trained manpower availability
- Make arrangements for all relevant machines and equipment for the testing of new products
- Execute the action plan, prepared basis the feedback received from customers
- Report line issues for improvement in production lines
- Take appropriate actions to address and resolve daily line quality issues
- Trained operators & Engineers defect, process, safety & skill upgradation
- Robot teaching, programming & trouble shooting
- Working here from new plant set up (green field project)
- Robot cell installation, programming and achieved designed output.
Engineer- Production
Best Koki Automotive Pvt Ltd
04.2016
- Achieve production targets as per schedule
- Teaching and programming welding robots, jig and fixture correction as per CMM
- Programming and handling troubleshooting activities of Welding Robot (ABB, KUKA & FANUC)
- Jig and fixture validation, process enhancement
- Ensure EOL inspection for Transmission tower and forks
- Doing fixture correction as per CMM
- Identify ways to reduce process costs through recommendation's i.e
- New process equipment, justification to improve performance
- Organize meetings with other team members to facilitate growth
- Improve continually existing operations, for increase quality, productivity, efficiency and cost savings.
Senior Engineer - Production
Rasandik Engineering Industries India Pvt Ltd
10.2011
- Programming and providing training as well as handling troubleshooting activities of Welding Robot (ABB)
- Drawing up production schedule and meeting all customers' requirements
- Searching, Negotiation and developing new vendors for cheaper and easy assessable spare instead of imported spares
- Making daily Check sheets and monthly preventive maintenance plan for TWB machine
- System documentation with respect to ISO/TS-16949
- Maintaining a log book of all problems that occur in a week & then taking Corrective actions
- Calculating MTTR, MTBF and OEE of machines and overall
- Maintaining spare parts list and maintain minimum inventory of spare parts
- Looking after maintenance of machine on a regular basis as well as maintaining its record in the check sheet
Education
Bachelor of Technology - EEE
Dr. A.P.J. Abdul Kalam Technical University Uttar Pradesh
05.2011
12th -
Janta Inter College, Nauhjheel, Mathura Uttar Pradesh
05.2007
10th -
Adarsh Inter College, Mitthauli Mathura Uttar Pradesh
05.2005
Skills
Manufacturing Management, Leadership, Manpower Management, shop floor control, Weld Shop, Press shop & Assembly production Management 4M Management, Welding's (MIG, SPOT, TIG, PROJECTION, LASER), TWB, Robot Programming (ABB, KUKA, Panasonic, Yaskawa), SAP, BOM, Production Management, TPM, SPQCDSM, Line balancing, Laser, New Line Set up, 5's, Kaizen, bottleneck Analysis, Productivity Improvements, KPI's Improvements, cycle time improvement, Cost reduction, shop floor control, Manpower Management, VA/VE, VSM, bottleneck analysis, fixture correction, green field projects
Certification
SAP PP Module
Accomplishments
- Increase Productivity in Kaizen Metal Forming up to 20% and reduce Manpower in Press & Weld shop save cost up to 2 Cr Annually.
- In Belrise industries Set up new plant and all robotic line and achieve desired production level than increase production 650 nos to 700 nos per shift of ACKA line.
- Change one ACKA line to AEEP Line and do programming of all robots.
- Manpower optimization "Done one robot cell manpower less in 3 frame body lines.
- Reduce rejection from 3% to 0.2 % in Best koki of Transmission fork doing fixture correction and programming and taking other corrective actions.
- Reduce manpower cost in Kaizen Metal from 13% to 8.75%.
- Increase YRA sleeve production from 750 nos to 1200 nos per shift in Best koki.
- Increase Sale of belrise plant from 0 to 25 Cr per month.
- Achieve SPR up to 85% & OEE up to 84.3%.
Additional Information
I, hereby submit that the information furnished here is true and that suitable references can be furnished upon specific request to that effect.
Trainingsattended
- Robot programming
- Industrial safety audit
- SPC
- PFMEA
- QSS Implementation
- Six sigma
- Lean manufacturing
- TPS
- TPM
- Shop floor control
- Visual Management
- IATF 2016:16949
Customers
- Suzuki Motors
- Suzuki Motors Gujarat
- Tata Motors
- Mahindra & Mahindra
- General Motors
- Hero Motors
- Honda Motors
- Force Motors
- Volkswagen
- Tafe Tractors
- Kubota Tractors
- CNH
- Renault
- Suzuki 2 wheelers
- HBSS
- HLI & Other Automotive OEM'S
Personal Information
- Date of Birth: 10/07/1989
- Gender: Male
- Nationality: Indian
- Marital Status: Married
Languages
Hindi and English
Software
SAP PP
Robot studio
MS office
Timeline
Manager - Production
Kaizen Metal Forming Pvt Ltd
10.2023 - Current
Assistant Manager - Production
Belrise Industries Pvt Ltd
08.2017
Engineer- Production
Best Koki Automotive Pvt Ltd
04.2016
Senior Engineer - Production
Rasandik Engineering Industries India Pvt Ltd
10.2011
Bachelor of Technology - EEE
Dr. A.P.J. Abdul Kalam Technical University Uttar Pradesh
12th -
Janta Inter College, Nauhjheel, Mathura Uttar Pradesh
10th -
Adarsh Inter College, Mitthauli Mathura Uttar Pradesh
Similar Profiles
Gabriel Vazquez CalvilloGabriel Vazquez Calvillo
Técnico SR. at San Luis Metal Forming SA de CV.Técnico SR. at San Luis Metal Forming SA de CV.
Gerardo LoeraGerardo Loera
Code Welder at Commercial Metal FormingCode Welder at Commercial Metal Forming
Nicolas MairaNicolas Maira
Maintenance Technician at Rollstar Metal FormingMaintenance Technician at Rollstar Metal Forming
Chetan SharmaChetan Sharma
PURCHASE MANAGER). TECHNICAL at VISHAL PIPES LIMITEDPURCHASE MANAGER). TECHNICAL at VISHAL PIPES LIMITED
Vishal BhardwajVishal Bhardwaj
Sr. Executive at DROETKER INDIA Pvt. LtdSr. Executive at DROETKER INDIA Pvt. Ltd