Sudesh Dessai
Bangalore
Summary
Multi-talented industrial, process, and continuous improvement engineering professional with a proven track record of driving operational excellence and business growth. Adept at designing, executing, and leading transformative process improvements that enhance efficiency, reduce costs, and enable scalable growth. A visionary leader with a strong history of guiding cross-functional teams and business operations toward sustained success.
Overview
10
10
years of professional experience
Work History
Senior Manager - Industrialization Assembly Process
Schneider Electric India Pvt Ltd
Bangalore
07.2023 - Current
- Participate in early product design and provide assembly process input to the product with respect to manufacturability, CAPEX, and ergonomics.
- Scheduling machine development timeline and ensuring adherence to the overall project timeline at different stages (Open gate to Sell gate).
- Drafting engineering estimations for semi-automatic and automatic machines, assembly lines with traceability (MES), and documenting detailed technical specifications for the suppliers to provide detailed quotations.
- Supporting the purchase to negotiate and finalize the supplier with engineering estimation.
- Participate in the detailed design of the machines with the supplier and finalizing the design by reviewing it with the CFT (Project and Plant Team); conducting trials, validation at the supplier as well as at the plant end, pilot run, and hand over machines to the plant.
- Providing detailed training on the operation of the machine, process sequence, maintenance, and MES.
- Responsible for product simplification and optimization from the assembly perspective, managing DFA and Line Architecture studies.
- Acted as the window between R&D and equipment suppliers to work out the best solution for assembly.
- Layout planning on the shop floor and creating efficient flow to ensure reduced material and man flow.
- Proposing and justifying investment versus assembly cost: the most economical manufacturing process architecture according to the rules of the Schneider Production System (SPS) and Line Architecture Design Methodology (LADM).
- Drafting/Reviewing Assembly Chronology (PFD), MFMEA, LADM, DFMEA, PFMEA, etc.
Process Engineer - Engineering
CommScope India Pvt Ltd
Verna
12.2021 - 07.2023
- Designed, installed, and commissioned improved assembly line layouts. Introduced a ball transfer unit conveyor to reduce 46% of the area and 40% of manpower compared to sending site (Mexico) for the same capacity (Transfer Project).
- Leading continuous improvement and automation projects as part of CCF and VSM workshops to improve productivity and reduce manpower (FOH, VOH, and Labor).
- Drafted bay layout, filled machines, and created efficient flow as a part of CCF workshops to optimize the process and overall efficiency, including space.
- Installed and commissioned cable cutting machines and product assembly lines for the entire business unit as per process layout, product layout, batch manufacturing, and single piece flow.
- Lead a team of eight process technicians to ensure a smooth process flow in shifts on the shop floor.
- Actively teamed to drive CCF and VSM workshops for 6 assembly lines, 2 manufacturing lines, and 6 re-coiler machines to ensure smooth man and material flow throughout the business unit, and optimum utilization of capacity.
- Improved FG material flow by optimizing man and material movement (eight wastes) and activity planning using time study. Further, reduced FG inventory and freed 600 sq. mts. of the space.
- Implemented Kanban and JIT to reduce the space of 415 sq. mts. and manage RM and WIP inventory.
- Designed jigs and fixtures and managed suppliers to meet the equipment and fixture requirements.
- SMED: Reduced cable re-coiler machine set-up time from 180secs to 35 secs i.e., 80% reduction, further improving machine utilization.
- Cost-saving champions: packaging improvement of $2 million annually, received the 'CommScope Star Award.'
- Drafted, approved and maintained Process Flow Diagram, Control Plan, Work instructions and PFMEAs.
- Recognized and rewarded with two 'CommScope Star Awards' for contributions towards layouts and process improvements.
Associate Lead Engineer - Operational Excellence
Rheinmetall Automotive India
Takwe
06.2021 - 12.2021
- Developed road map for the implementation of Business Excellence strategy in the plants.
- Successfully drafted 6S implementation structure and implemented 6S on the shop floor, R G R structure developed to evaluate and improve monthly performance.
- Completed DMAIC project on scrap reduction. Total scrap reduction from 4% to 1.8%.
- Implemented 3 pillars of TPM-Focused improvement, Planned Maintenance and Autonomous maintenance.
- Conducted training session for operators and middle management on lean tools.
- Reduced press shop operator spaghetti, improved operator movement time from 55 mins to 13 mins, reduction of 76% by re-layouting.
- Drafted and implemented standard work on shop floor.
- Implemented visual factory on shop floor.
Associate Lead Engineer - Industrial Engineering
Rheinmetall Automotive India
Takwe
11.2017 - 12.2020
- SMED G 5s: Improved fine boring process set up time by identifying internal and external activities and introducing Tool Pre-setter equipment, Set-up time reduced from 45 mins to 15 mins, 33% reduction.
- Improved cycle time of fine boring process from 9 secs to 6 secs by improving machine process sequence. Further reduction in cycle time by 33%.
- Improved Fine boring cutting tool geometry from orthogonal to oblique cutters to divert chips and improved chip breaker geometry.
- Calculated and maintained Capacity calculation of the manufacturing lines.
- Deputed to Germany to transfer half plain bearing manufacturing technology from sister plant.
- Installed and commissioned plant machineries as per business requirement.
- SPM: Developed conveyor type ultrasonic cleaning machine for the Half Plain Bearing.
- Machine modifications: refurbishment or modification of the existing machines as per capacity requirements.
- Conducted feasibility studies for the new product requirement.
- Conducted periodic process capability studies to monitor process health.
- Drafted and approved Work Instruction manuals, Control Plans and maintained PFMEAs for the process.
Process Engineer - Industrial Engineering
Rheinmetall Automotive AG
Papenburg
01.2018 - 06.2019
- Responsible for transfer of equipment and process knowledge within inter entity from Germany to India.
- Training as process specialist for internal turning operation for micro grooving (Fine boring Technology).
- Wrote technical document to evaluate quality of 'Press bending operation.'
- Trained Indian technicians and supervisors to operate and maintain German machines and equipment's.
- Assisted Continuous Improvement Engineer in implementation of KANBAN on the shop floor.
Quality Engineer
Kineco Kaman Composites India Pvt
Pilerne
06.2015 - 11.2017
- Dimensional inspection of carbon fiber composite assembly parts and assembled structures using a portable CMM-Faro Edge Arm.
- Thorough in reading drawings of Boeing and Airbus, good knowledge of GDGT, tolerance stack up.
- First Article Inspection (FAI) as per AS9102.
- Non-destructive Testing of Carbon, aramid, Glass fiber parts and assemblies NDT-Level-II in UT as per ASNT (SNT-TC-1A).
Education
BE - Mechanical Engineering
SJC Institute of Technology
Karnataka01.2014
Skills
- Lean Six Sigma Green Belt
- Process flow diagram (PFD)
- Time study
- Line balancing
- Process improvement and management
- Work instruction
- Plant layout
- PFMEA
- MFMEA
- CAPEX
- Ergonomics
- Assembly Line & Work Station
- Control plan
- CCF workshop
- VSM Workshop
- KANBAN
- JIT
- Process metrics
- KAIZEN
- SMED
- LPA
- TPM
- Manufacturing line
- ASNT Level 2 UT
- Minitab
- SolidWorks
- Ergonomics
Websites
Accomplishments
- Process improvement, improved packaging of the product, saving $2 million per year, received star award at CommScope
- Layouts and line installation, designed layout, installed four assembly lines with a conveyor system, and ramped up efficiency from 40% to 94% in a two-month period
- Project on-time delivery, delivered line installation, and commissioning project with operator training within the timeline, received STEP-UP recognition at Schneider Electric
Languages
Konkani
First Language
English
Proficient (C2)
C2
Marathi
Proficient (C2)
C2
Hindi
Advanced (C1)
C1
Kannada
Beginner (A1)
A1
Timeline
Senior Manager - Industrialization Assembly Process
Schneider Electric India Pvt Ltd
07.2023 - Current
Process Engineer - Engineering
CommScope India Pvt Ltd
12.2021 - 07.2023
Associate Lead Engineer - Operational Excellence
Rheinmetall Automotive India
06.2021 - 12.2021
Process Engineer - Industrial Engineering
Rheinmetall Automotive AG
01.2018 - 06.2019
Associate Lead Engineer - Industrial Engineering
Rheinmetall Automotive India
11.2017 - 12.2020
Quality Engineer
Kineco Kaman Composites India Pvt
06.2015 - 11.2017
BE - Mechanical Engineering
SJC Institute of Technology
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