SUDARSHAN JOSHI
Pune
Summary
Results-oriented Manufacturing Section Manager experienced in machine shop control, preventive maintenance planning, and workforce leadership. Achieved significant cost reductions, including halving outsource processing costs and cutting setup times by 25% through lean manufacturing initiatives and digital shop-floor transformations. Focused on driving operational performance and business growth through expertise in capacity planning, smart factory technologies, and building high-performing teams.
Overview
1
1
Language
22
22
years of professional experience
Work History
Section Manager Manufacturing (Team Lead)
Forbes Marshall Pvt Ltd
Pune
07.2007 - Current
- Capacity & Production Planning: Formulated capacity expansion plans using Oracle ERP (R12 / ASCP) to meet growth targets; managed machining and painting schedules to satisfy HUB and reservation demand while ensuring on-time delivery.
- Lean Initiatives & Capacity Growth: Championed SMED and lead time reduction projects that increased in-house capacity, driving a 25% reduction in setup times and slashing Outsource Processing (OSP) costs from 1.0% to 0.5% of total sales turnover.
- Optimised machining processes and led cost-saving initiatives, reducing operational overheads, minimising scrap, and ensuring product durability and quality.
- Digital Transformation & Continuous Improvement: Spearheaded the integration of smart technology including automated capacity modules for machine shop capacity identification and digital inventory management; implemented CNC machine automation, real-time monitoring, and predictive maintenance to boost productivity and reduce downtime.
- Collaborated with production, quality, and safety teams to schedule maintenance activities, assess equipment readiness, and enforce adherence to preventive maintenance plans.
- Enforced shop-floor discipline and conducted safety audits aligned with legal standards; maintained 5S cleanliness, trained new employees, and developed an agile, multitasking workforce.
Production Officer
Indo Scottle Auto Parts Pvt Ltd
Pune
06.2006 - 07.2007
- Programmed and operated CNC turning machines, optimising machining processes to enhance production quality.
- Managed setup processes by coordinating tooling selection and machine calibration for seamless production transitions.
- Enforced quality control plans and actively supported plant safety programs, minimizing workplace injuries.
- Monitored and analysed daily production reports to ensure compliance with documentation standards and maintain operational integrity.
Production Officer
Kalyani Forge Ltd
Pune
05.2005 - 06.2006
- Supervised setup processes and calibrated machinery for seamless batch changeovers, analysing production data to uphold quality standards.
- Led new product development setups by selecting tooling and machining strategies, enhancing overall plant production capabilities.
- Programmed and operated CNC turning and SPM machines, ensuring high precision in component manufacturing.
Education
Post-Baccalaureate Diploma - Mechanical Engineering
HKE'S Polytechnic
Kalaburagi10-2004
Bachelor of Technology - Mechanical Engineering
Vishwa Hindu Collage ( JRN University )
Kalaburagi06-2011
Skills
- Operations & Shop Floor Management: Shop Floor Control, Production Planning, Capacity Planning, Resource Allocation, Workforce Management
- Continuous Improvement & Lean: SMED (Single-Minute Exchange of Die), Lead Time Reduction, Lean Manufacturing, Process optimisation, 5S organisation, Cost-saving initiatives
- Preventive Maintenance & Reliability: Preventive maintenance, Equipment Readiness, Downtime Reduction, Predictive Maintenance
- Machining & Process Engineering: CNC/VMC/HMC Machining, Tooling Selection, Machine Calibration, Quality Assurance, Safety Protocols
- Quality control
- Digitalisation & Systems: Oracle ERP R12 / ASCP, Smart Factory Automation, CATIA V5 CAD Software
- ERP & Engineering Tools: Oracle ERP (R12, ASCP), Catia V5, CAD Software
TECHNICAL & LINGUISTIC PROFICIENCY
Languages: English (Advanced - C1), Hindi (Proficient - C2), Marathi (Proficient - C2), Kannada (Native).
Accomplishments
- Outsource Cost Optimization: Halved Outsource Processing (OSP) expenses from 1.0% to 0.5% of total sales value by improving in-house manufacturing capacity through targeted lead time reduction and SMED initiatives.
- Setup & Changeover Efficiency: Spearheaded Single-Minute Exchange of Die (SMED) projects across machining centers, successfully cutting setup time by 25% to maximize spindle uptime and line flexibility.
- National Industry Recognition: Honored with 1st Prize in national productivity contests by both INSAAN (2022–2023) and the Indian Institution of Industrial Engineering (IIIE, 2021–2022).
- Excellence in Engineering: Conferred the “Best Manufacturing Engineer” award at Forbes Marshall (2018–2019).
- Travelled onsite to Fukushima, Japan to Tungaloy for tooling conferance.
HONORS & AWARDS
1st Prize – Productivity Contest (Medium and Small Scale Category): INSAAN (2022–2023), 1st Prize – Productivity Contest (Medium and Small Scale Category): Indian Institution of Industrial Engineering (IIIE) (2021–2022), Best Manufacturing Engineer: Forbes Marshall (2018–2019)
ACTIVITIES & SOCIAL INITIATIVES
Participated in tree plantation drive at Sawardari, Chakan, Pune.
Timeline
Section Manager Manufacturing (Team Lead)
Forbes Marshall Pvt Ltd
07.2007 - Current
Production Officer
Indo Scottle Auto Parts Pvt Ltd
06.2006 - 07.2007
Production Officer
Kalyani Forge Ltd
05.2005 - 06.2006
Post-Baccalaureate Diploma - Mechanical Engineering
HKE'S Polytechnic
Bachelor of Technology - Mechanical Engineering
Vishwa Hindu Collage ( JRN University )