Tapan Das
Delhi NCR
Summary
A strategic, visionary, and competent operations leader with over 24 years of hands-on experience in manufacturing engineering, project management, supply chain management, and operational excellence across top-tier automotive brands. Seeking a challenging and high-impact leadership position in a progressive organization where deep expertise in end-to-end project lifecycle management, global supply chain strategy, automation-driven manufacturing, and cross-functional team leadership can be leveraged to deliver transformative results, enhance operational agility, and contribute to long-term business sustainability and competitive advantage.
Overview
25
25
years of professional experience
Work History
Manager (Sec In charge) New Model Development & Cost control
Honda Cars India Ltd.
03.2013 - Current
- Leading new model development projects, driving procurement strategies, and overseeing infrastructure planning and setup for manufacturing readiness.
- Streamlining vendor selection processes, conducting contract negotiations, and implementing cost-saving supplier agreements to enhance compliance and reduce expenses.
- Applying FIFO, ABC, and FSN inventory analysis techniques to minimize stockouts, reduce carrying costs, and improve overall material flow and operational efficiency.
- Leveraging Six Sigma and other lean methodologies to optimize production processes, reduce cycle times, and enhance product quality and reliability.
- Managing international trade operations, ensuring customs clearance compliance, and optimizing freight forwarding logistics to support a seamless global supply chain.
- Partnering with legal teams, procurement specialists, and senior management to ensure seamless execution of supply chain activities and regulatory adherence.
- Developing and maintaining KPI dashboards, MIS reports, and performance metrics to facilitate informed and timely leadership decisions.
- Ensuring new models meet stringent quality and reliability standards through rigorous testing and consistent parts supply management.
- Managing supplier relationships, optimizing material packing, staging, and delivery schedules to meet production timelines efficiently.
- Applying lean manufacturing principles and process improvements to drive operational excellence and revenue growth across new model launches.
- Realized ₹60/car cost savings for CITY & AMAZE models by architecting an innovative sub-assembly planning strategy.
- Generated ₹170/car savings through optimization and redesign of packaging processes, reducing material and transit inefficiencies.
- Achieved ₹1 million cost avoidance by pioneering in-house robotic programming for new model automation, eliminating third-party dependency.
- Accelerated manufacturing cycle times by 10% by streamlining workflows and driving precision-focused operational enhancements.
- Boosted production efficiency by 25% via strategic deployment of robotic welding systems and lean-driven process re-engineering.
Senior Engineer - Production- Shift In-Charge
Maruti Suzuki India Ltd.
Manesar
11.2008 - 03.2013
- Supervised over 230 operators and 8 engineers in robotic welding operations, consistently exceeding daily production targets and maintaining high-quality output.
- Spearheaded development and installation of new tooling systems and commissioned production lines, resulting in improved efficiency and significant cost savings.
- Introduced and managed preventive maintenance programs for Fanuc robots, reducing unplanned downtime by 15% and extending equipment life.
- Facilitated comprehensive training programs focused on safety compliance, quality standards, and continuous improvement, enhancing team performance and adherence to SOPs.
- Identified and eliminated process inefficiencies, leading to reduced cycle times and production costs while maintaining product quality standards.
- Collaborated with maintenance, quality, and planning teams to ensure seamless shift transitions and alignment of production goals with organizational objectives.
Senior Engineer - Process Engineering
Caparo Engineering India Pvt Ltd.
India
02.2008 - 11.2008
- Designed and executed manual and automated welding systems to achieve balanced line operations and consistent weld quality.
- Ensured process capability and compliance with SOP targets, maintaining high-quality standards throughout pilot and production phases.
- Led new model development from initial concept through SOP handover, guaranteeing robust process design and launch readiness.
- Worked across Engineering, Quality, and Production teams to implement process improvements that enhanced capability and reduced cycle times.
- Developed and maintained detailed SOPs and work instructions, aligning process execution with safety, quality, and efficiency benchmarks.
Officer - Production Welding
H-One India Pvt Ltd.
India
07.2005 - 01.2008
- Oversaw ABB and Fanuc robotics welding systems, ensuring high-quality output and consistent throughput; implemented robust process controls and real-time troubleshooting to minimize downtime, defects, and rework while aligning with SOP and ISO standards.
- Led preventive maintenance scheduling in coordination with engineering teams to ensure equipment efficiency and reliability; enforced strict safety protocols, reducing incidents, and promoting a safe, compliant working environment.
Engineer - Process & Planning
Mark Exhaust System Ltd.
India
12.2000 - 06.2005
- Streamlined material planning, production scheduling, and inventory control to enhance delivery performance, improve workflow from raw material to dispatch, and reduce overall lead times across operations.
- Conducted in-depth cost analysis and implemented strategic process enhancements to boost productivity, optimize resource utilization, and minimize material wastage on the production floor.
Education
P.G. Diploma - Logistics & Supply Chain Management
Indian Institute of Materials Management
Bachelor of Commerce -
Dr. A.P.J. Abdul Kalam University
Diploma in Mechanical Engineering -
S.C.T. E & V.T
Diploma in Contract Management -
Skills
- Manufacturing Engineering
- Logistic management
- Supply chain & logistic
- Project management-Greenfield
- New Model Development
- Robotic & Automation
- Freight management
- CAPEX & OPEX Planning
- Lean Manufacturing
- Operational excellence
- Trade documentation
- Global sourcing & procurement
- Vendor development
- P&L oversight
- Contract management
- Sustainability & ESG compliance
- Process planning
- EXIM operation
- Custom compliance
- KPI development & MIS reporting
Accomplishments
- Realized ₹60/car cost savings for CITY & AMAZE models by architecting an innovative sub-assembly planning strategy.
- Generated ₹170/car savings through optimization and redesign of packaging processes, reducing material and transit inefficiencies.
- Achieved ₹1 million cost avoidance by pioneering in-house robotic programming for new model automation, eliminating third-party dependency.
- Accelerated manufacturing cycle times by 10% by streamlining workflows and driving precision-focused operational enhancements.
- Boosted production efficiency by 25% via strategic deployment of robotic welding systems and lean-driven process re-engineering.
Projects Handled
- Greenfield Plant Project, 2013, Established a state-of-the-art manufacturing facility from the ground up, overseeing end-to-end infrastructure planning, layout design, vendor finalization, and equipment commissioning aligned with CAPEX plans.
- Automation Line Setup, 2013, Led the successful implementation of robotic welding automation using ABB and Fanuc systems to enhance precision, reduce cycle time, and improve operational efficiency in the body welding shop.
- Milk Run Logistics & WMS Implementation, 2014 & 2015, Optimized inbound logistics through the introduction of the Milk Run model, reducing transportation costs and improving supplier delivery reliability; concurrently implemented a Warehouse Management System (WMS) to streamline material flow and inventory accuracy.
- New Model Introductions, 2013 - Present, Managed procurement and production readiness for multiple successful new model launches including AMAZE, CITY, HEV, JAZZ, WRV, and ELEVATE, coordinating with cross-functional teams and global suppliers to ensure on-time execution and cost control.
Personal Information
Date of Birth: 06/19/79
Languages
- English
- Hindi
- Odiya
- Japanese (beginner)
Key Strengths
Experience within the automotive manufacturing sector, focusing on production engineering, supply chain integration, and new model development. Proven ability to drive operational excellence in high-volume, quality-sensitive environments with a strong emphasis on automation and lean manufacturing., Expertise in planning and executing greenfield projects and new model introductions, ensuring alignment with CAPEX budgets and timelines. Adept at integrating robotic welding and automation systems to optimize production flow and reduce cycle times. Skilled in infrastructure planning and cross-functional coordination to deliver scalable manufacturing solutions., Strong capability in strategic sourcing, vendor development, and contract negotiations to optimize procurement costs and supplier performance. Experienced in managing multimodal logistics operations, including customs clearance and freight forwarding, to enhance supply chain resilience. Proficient in inventory optimization techniques such as FIFO, ABC, and FSN analysis to minimize stockouts and reduce carrying costs., Knowledgeable in deploying robotic automation solutions (ABB, Fanuc, Yaskawa) to improve production accuracy and throughput. Skilled in utilizing ERP systems like SAP MM/PP and Warehouse Management Systems (WMS) to streamline procurement and inventory control. Proficient in leveraging business intelligence tools such as Power BI for KPI monitoring and decision support., Expert in managing export-import documentation, customs regulations, and trade compliance to ensure seamless international shipments. Experienced in coordinating with regulatory bodies and aligning operations with ECGC and global trade policies. Capable of optimizing freight and logistics strategies to reduce costs and delivery lead times., Demonstrated ability to lead large cross-functional teams, fostering collaboration and accountability to meet business objectives. Experienced in managing stakeholder relationships across procurement, legal, and executive management for aligned project execution. Skilled in training and mentoring staff to build capability and sustain operational excellence.
Timeline
Manager (Sec In charge) New Model Development & Cost control
Honda Cars India Ltd.
03.2013 - Current
Senior Engineer - Production- Shift In-Charge
Maruti Suzuki India Ltd.
11.2008 - 03.2013
Senior Engineer - Process Engineering
Caparo Engineering India Pvt Ltd.
02.2008 - 11.2008
Officer - Production Welding
H-One India Pvt Ltd.
07.2005 - 01.2008
Engineer - Process & Planning
Mark Exhaust System Ltd.
12.2000 - 06.2005
P.G. Diploma - Logistics & Supply Chain Management
Indian Institute of Materials Management
Bachelor of Commerce -
Dr. A.P.J. Abdul Kalam University
Diploma in Mechanical Engineering -
S.C.T. E & V.T
Diploma in Contract Management -
Similar Profiles
Ravi Kumar JhaRavi Kumar Jha
Assistant Manager - Accounts & Taxation at Honda Cars India LtdAssistant Manager - Accounts & Taxation at Honda Cars India Ltd
KAPIL GUPTAKAPIL GUPTA
Quality Assurance Manager at Honda Cars IndiaQuality Assurance Manager at Honda Cars India
ANURAG CHOPRAANURAG CHOPRA
Manager – Quality Engineering – Chassis at HONDA Cars India LtdManager – Quality Engineering – Chassis at HONDA Cars India Ltd
Dhruv MahajanDhruv Mahajan
Assistant Manager - Technology Sales & Solutions at TO THE NEWAssistant Manager - Technology Sales & Solutions at TO THE NEW
Munish WaliaMunish Walia
Engagement Manager at Net SolutionsEngagement Manager at Net Solutions