SONU KUMAR

• Spearheaded the greenfield project for engine assembly and optimizing production line setups.
• Created essential documentation and check sheets for quality assurance.
• Executed manpower planning aligning human resources with project goals to enhance efficiency.
• Engaged in operator training and development activities to boost assembly line performance.
• Conducted root cause analysis to troubleshoot mechanical issues in production lines.
• Analyzed production processes to identify areas for efficiency improvements and cost reduction.
• Worked with cross-functional teams to achieve goals.
• Utilized various software and tools to streamline processes and optimize performance.
• Achieved cost-savings by developing functional solutions to problems.
• Guided team members through task priorities and work instructions.

Process Engineer-Vehicle Assembly Line

• Established project milestones, objectives, budgets, timelines, and resource allocations.
• Updated process layouts, equipment requirements, and engineering specifications for new products
• Analyzed data from experiments to determine best practices for current processes.
• Implemented unique methods and methodologies, which helped reduce, and resolve issues.
• Reviewed production workflows to identify waste, delays, and equipment bottlenecks
• Ensured compliance with relevant industry regulations regarding health and safety standards.
• Performed regular maintenance checks on all equipment used in the assembly line.
• Developed strategies for improving product quality while minimizing production times.
• Implemented innovative ideas for increasing productivity while reducing waste output.
• Monitored operational costs associated with the manufacturing process and identified areas for cost reduction initiatives.
• Implemented continuous improvement in processes and materials to improve performance and reduce costs.

• Supported end-to-end production operations to meet daily, weekly, and monthly targets.
• Maximum manpower, machines, materials, and shop-floor resources efficiently.
• Tracked production performance and supported improvements in productivity, quality, cost, and delivery.
• Led and supervised production teams while maintaining operational standards and discipline.
• Applied lean manufacturing, Kaizen, 5S, and TPM practices to improve efficiency.
• Assisted with continuous improvement work to reduce waste, shorten cycle time, and raise throughput.
• Monitored OEE and took corrective action to reduce downtime.
• Worked with maintenance, quality, stores, and supply chain teams to keep operations running smoothly.
• Performed root cause analysis and supported CAPA for production and quality issues.
• Followed safety, quality, environmental, and statutory requirements.

• Coordinated workflow to maximize efficiency in the production line.
• Coordinated training sessions for new employees on safety and quality standards.
• Implemented process improvements to enhance workflow efficiency within the team.
• Monitored equipment performance and scheduled maintenance to prevent downtime.
• Delegated daily tasks to team members to optimize group productivity.
• Updated and maintained databases with current information.
• Operated equipment and machinery according to safety guidelines.

• Achieving daily production targets, Assessing drops in productivity and instituting corrective actions.
• Modifying and simplifying the existing standard operating procedures for improving the productivity, quality, safety and delivery
• Conducting meetings with Line operator and discussing productivity, quality and safety related issues regularly.
• Ensuring calibrations and testing of tools, tackles and equipment's.
• Responsible for multi-skilling and operators training.
• unsafe acts & unsafe conditions (HIRA) and eliminating them to avoid the accidents
• Ensuring shop floor 5S.