Suhas Mohan Joshi

Project Execution:

1. Project Planning

• Prepare detailed project execution plans (scheduling, resource planning, budgeting).
• Define project scope, deliverables, and key milestones based on customer requirements and internal capabilities.

2. Coordination and Communication

• Coordinate with internal departments (Design, Purchase, Production, Quality, Logistics) and external stakeholders (vendors, customers).
• Lead project review meetings and provide project status updates to management and clients.

3. Resource Mobilization

• Ensure availability of manpower, machinery, tools, and materials at project sites or shop floors.
• Identify and mitigate resource gaps proactively.

4. Monitoring and Execution

• Monitor project progress against the plan to ensure timely completion.
• Ensure compliance with design specifications, safety standards, and quality norms during execution.

5. Risk Management

• Identify potential risks (technical, material, schedule risks) early and develop mitigation strategies.
• Solve project-related issues promptly to avoid project delays or cost overruns.

6. Quality Assurance

• Ensure that executed work meets technical and quality standards.
• Liaise with the QA/QC team for inspections, testing, and certifications where required.

7. Budget and Cost Control

• Monitor project budgets; control expenses related to manpower, materials, and subcontracting.
• Identify cost-saving opportunities without compromising project quality.

8. Documentation and Handover

• Maintain complete project documentation (drawings, change requests, completion reports, etc.).
• Support project handover activities to customers or internal teams after successful execution.

Production Planning & Control (PPC):

• Develop and implement production schedules based on customer orders, forecasts, and inventory levels.
• Monitor daily production performance and adjust schedules to meet delivery commitments.
• Optimize resource utilization (manpower, machines, materials) to maximize efficiency.
• Coordinate with procurement for timely availability of raw materials and components.
• Track WIP (work-in-progress), inventory levels, and lead times.
• Maintain accurate records of production data, variances, and delays.
• Plan and oversee execution of new and ongoing customer projects from initiation to completion.
• Coordinate with cross-functional teams (engineering, production, QA, logistics) to ensure project milestones are met.
• Identify and mitigate risks affecting project delivery timelines or costs.
• Ensure compliance with technical specifications, quality standards, and customer requirements.
• Track project budgets, timelines, and resource allocations.
• Communicate regularly with customers, suppliers, and stakeholders on project progress and issues.

Press/Machine shop Roles and responsibility

• Plan, schedule, and supervise daily press shop operations to meet production targets.
• Lead, mentor, and develop press shop staff, including supervisors, operators, and technicians.
• Oversee the setup and operation of mechanical and hydraulic presses, including progressive and transfer dies.
• Ensure adherence to quality control procedures and compliance with ISO or other regulatory standards.
• Manage tooling maintenance, press availability, and equipment reliability.
• Collaborate with engineering, quality, and maintenance teams to resolve production issues.
• Implement lean manufacturing principles, 5S, and other continuous improvement initiatives.
• Monitor KPIs such as output, downtime, scrap rates, and efficiency.
• Enforce strict adherence to health and safety standards across the press shop.
• Prepare and manage departmental budgets and resource planning.

Fabrication Roles and responsibility

• Lead and manage all fabrication shop operations, including planning, welding, assembly, inspection, and dispatch.
• Review project requirements and develop fabrication execution plans in coordination with engineering and project management teams.
• Ensure compliance with relevant industry standards (e.g., ASME, API, AWS, ISO) and client specifications.
• Monitor production progress and performance against the schedule and budget; implement corrective actions when needed.
• Coordinate material procurement, manpower, and equipment availability to support efficient fabrication.
• Liaise with QA/QC teams to ensure proper inspection, testing, and documentation at all fabrication stages.
• Maintain strict adherence to safety procedures and promote a strong safety culture in the fabrication yard.
• Drive productivity improvements, cost control, and waste reduction through lean fabrication practices.
• Interface with clients and third-party inspectors during fabrication stages, audits, and FATs (Factory Acceptance Tests).
• Maintain accurate fabrication records, reporting, and documentation.

• Production Planning:
• Develop and maintain detailed production plans based on demand, reservoir data, and well performance.
• Forecast future production volumes and optimize well allocation.
• Coordinate with drilling and completion teams to ensure timely well hookups.

Scheduling and Monitoring:

• Create detailed production schedules for each well and production facility.
• Monitor production rates and identify potential bottlenecks or operational issues.
• Track key performance indicators (KPIs) like production volumes, downtime, and efficiency.

Cost Control:

• Analyze production costs and identify areas for cost optimization.
• Monitor and manage operational expenses related to production activities.

Reporting and Analysis:

• Generate regular production reports, including performance metrics and trend analysis.
• Preparing a future state map that uses of Lean tools such as kaizen, TPM, VSM, POKA-Yoke, lean techniques to eliminate waste and improve customer value in the short to mid-term.
• Identify areas for improvement and implement corrective actions.

Collaboration:

• Work closely with various departments including sales, reservoir engineering (project), facilities engineering (Design/Programming), and operations teams to ensure smooth production operations.
• Daily/Weekly discussion with subcon team related projects completion.
• Communicate production plans and issues to relevant stakeholders.
• Performed root cause analysis and implemented corrective actions.
• Supervised entire production process and prepared proper documentation for dispatch.
• Inspected all machines and equipment and provided necessary repairs.
• Communicated with other team members to enhance process and performance.
• Conducted root cause analysis on equipment failures, leading to increased reliability and reduced downtime.
• Collaborated with R&D department to integrate new technologies into existing production systems, increasing automation capabilities.
• Analyzed production data to identify trends and areas of opportunity for process improvements, resulting in significant cost savings.
• Led a cross-functional team to identify bottlenecks in the production line, improving overall throughput.
• Optimized production processes by implementing lean manufacturing principles, resulting in reduced waste and increased efficiency.
• Conducted trials to determine equipment and machine performance capabilities.
• Mitigated supplier risk through investigation and sourcing of qualified suppliers and on-site evaluations of processes and capacities.
• Identified appropriate methodology to shorten cycle time and achieve target margins.

• Roles and responsibility
• Head of department handling team of engineers and 80 workmen.
• Ensuring smooth & timely execution as per contract in terms of Production requirement.
• Co-ordination with Planning and quality team to meet the entire quality & production requirement.
• Handle manpower for the optimized utilization.
• Preparation of manufacturing processes with respect to job requirement and monitor for the smooth execution
• Job Description
• Understand full Drawing, specifications and process requirement of the order.
• Plan with Manufacturing Head/Planning for the raw materials, hardware and Subcon requirement.
• Prepare the manufacturing schedule with manufacturing Head.
• Co-ordinate with QA team & welding team to get latest QAP, NDE procedures, WPS, PQR etc.
• Work allocation to shop floor and proper utilization of manpower.
• Daily monitoring of shop floor work and manpower utilization.
• Co-ordination with Planning & QA for any query in related documents.
• NCR raised for the non-conformity during any stage of inspection to be resolve with the defined time period.
• Responsible for the good housekeeping of shop floor.
• Responsible for maintaining the Tools & Tackles and Machines for allocated production area.
• Improving the manufacturing process day by day.
• MIS Reporting and any task given by management
• Handling major suppliers like JSW, TATA, USHA MARTINE and etc.
• Monitoring OEE level on daily basis.
• Solid experience with Microsoft Office Excel, Word, and Outlook , Solid use of PowerPoint and the ability to present to Sr. Leadership level.
• Total experience in ESAB – 3+ Year
• Read and analyzed blueprints and project documentation to develop workflows and strategies.
• Created engineering documentation for manufacturing processes, equipment specifications and change notices.
• Completed and submitted monthly and yearly reports to support executive decision making.
• Created proposals for equipment and instrument implementation to increase productivity and reduce maintenance expenses.

1. Line Operations Management

• Supervise the entire vehicle assembly process on the line, ensuring smooth and efficient operations.
• Monitor the flow of vehicles through different stations (chassis build, body mounting, engine installation, interior fitment, etc.).
• Ensure daily production targets (units per shift) are met without compromising quality.

2. Quality Control

• Check that each assembly stage meets the specified quality standards.
• Immediately address defects, deviations, or process non-conformities on the line.
• Work with the Quality Control (QC) team for in-line inspections and final audits.

3. Workforce Management

• Allocate manpower effectively across different assembly stations.
• Supervise, motivate, and guide line workers, technicians, and supervisors.
• Conduct daily briefings (toolbox talks) to communicate production plans, safety instructions, and improvement areas.

4. Process Adherence and Improvement

• Ensure Standard Operating Procedures (SOPs) are followed strictly at each station.
• Identify bottlenecks or delays and implement corrective actions quickly.
• Drive continuous improvement initiatives such as Kaizen, 5S, Lean Manufacturing, and Poka-yoke (error-proofing).

5. Equipment and Tool Management

• Ensure all tools, fixtures, and equipment on the assembly line are maintained and calibrated.
• Raise maintenance requests promptly for breakdowns to minimize downtime.

6. Safety Compliance

• Enforce personal protective equipment (PPE) usage and safe working practices.
• Lead safety drills, risk assessments, and incident investigations if any accidents occur.

7. Coordination and Communication

• Coordinate with other departments like Paint Shop, Body Shop, Logistics, and Quality.
• Participate in daily production meetings and escalate critical issues immediately.

8. Production Reporting

• Maintain shift-wise records of production output, rework, downtime, and manpower utilization.
• Analyze data and submit daily, weekly, and monthly reports to Production Management.

9. Training and Development

• Identify skill gaps among line workers and arrange technical and safety training.
• Train new employees on assembly processes and company standards.

10. Inventory and Material Handling

• Monitor availability of parts, sub-assemblies, consumables, and tools required for the line.
• Communicate with Material Planning and Logistics teams to avoid shortages or delays.

1. Body Assembly Process Management

• Supervise and control all body-in-white (BIW) fabrication activities, including welding, framing, and fitting.
• Manage the sequence of operations for assembling large panels like floor assemblies, roof panels, side frames, front/rear structures, etc.
• Ensure that jigs, fixtures, and robotic/manual welding stations are properly aligned and functioning.

2. Quality Assurance

• Ensure dimensional accuracy and structural integrity of the vehicle bodies.
• Conduct regular in-line inspections for weld quality (spot weld, MIG/MAG welds) and fixture fitting accuracy.
• Implement immediate corrective actions for detected defects — dents, misalignments, improper welds, etc.

3. Welding and Joining Operations

• Supervise welding operations including spot welding, arc welding, MIG welding, and resistance welding.
• Ensure correct welding parameters and techniques are followed to meet strength and safety standards.
• Conduct visual inspections and non-destructive tests (NDT) like ultrasonic or dye penetrant tests when required.

4. Line and Workforce Management

• Plan daily production schedules based on targets for different models (LCV/HCV variants).
• Assign workers to different zones: Framing station, Sub-Assembly station, Panel Assembly station, etc.
• Motivate and monitor technicians, welders, and operators for consistent productivity and quality.

5. Equipment and Jig/Fixture Management

• Ensure all body jigs, clamps, robots, and fixtures are regularly maintained, calibrated, and repaired.
• Collaborate with the maintenance team for preventive maintenance and quick breakdown resolution.

6. Safety and Compliance

• Enforce strict adherence to safety norms, especially regarding welding operations (fumes, sparks, burns).
• Ensure usage of PPEs: gloves, helmets, safety glasses, welding shields, etc.
• Conduct regular safety audits and hazard identification exercises.

7. Process Improvement

• Continuously identify and eliminate waste (waiting time, rework, excess motion) from the assembly line.
• Implement Lean Manufacturing principles like Kaizen, 5S, Standard Work, and Poka-yoke solutions.
• Participate in productivity improvement and cost-saving projects.

8. Training and Skill Development

• Regularly train welders and fitters on new models, updated welding techniques, or revised assembly procedures.
• Conduct refreshers on quality standards and safety practices.

9. Cross-Functional Coordination

• Work closely with Design/Engineering teams during model changes or New Product Development (NPD).
• Interface with Paint Shop for body surface quality feedback.
• Liaise with Quality Assurance and Manufacturing Engineering teams for line audits and improvements.

10. Reporting and Documentation

• Maintain detailed logs for production numbers, defects/rework, downtime, and welding tests.
• Prepare daily shift reports and participate in Production Review Meetings.