Vysakh J Menon
Navi Mumbai
Summary
Production Engineer with 8+ years of experience in industrial production and process. Being familiar in most of the mechanical processes, process improvement activities, and using various problem-solving tools, I am able to plan a scenario with higher output and greater optimization.
Overview
9
9
years of professional experience
1
1
Certification
Work History
Production Manager
Copiam Consumer Care Pvt Ltd
Panvel
03.2023 - Current
- Commissioning the set up of a new production line for candles which involves 60 meter conveyor, melters, pusher assemblies and a filling line, entire project valued at approx. 7 Cr
- Overlooking the entire operations of the factory including new project, planning, purchase, commissioning, production, quality and maintenance of the candle manufacturing company
- Bringing up the efficiency of machines from scratch.
- Performing hourly bottleneck management to identify bottlenecks and work on a permanent solution for the same
- Setting up of ERP workstations and process flow and traceability by understanding the demands from multiple functional heads and implementing the same by coordinating with ERP consultant
- Preparation of Production Planning as per the incoming sales order and using inventory management systems such as JIT
- Leading a team of over 100 members to implement the day to day production activities including Production, Research & Development, Trials, Installation of Machines and calibration of the same as per requirement
- Overlooking documentations such as SOP, VO, BMR, OPCR, MIS, ECO.
- Weekly meeting with purchase dept. for stock verification and revisiting all inventory valuation and ensure respective inventories are above the re order level
- Dealing with various vendors for various requirements through rigorous negotiations at the same time maintaining a good relationship
- Implementing 5S standards in the shop floor
- Preparation of documentation related to production, quality and maintenance as per ISO format
- Ensuring equal skilled laborers in all 3 shifts to maintain maximum productivity
- Daily Updating of Production related tasks, progress and new product development with the director
- Calculating the landed costs of the products after CIF or FOB and summarizing the price of the FG and also verifying the same from ERP software by adding subsequent charges to ensure no unaccounted loss is incurred during operations
- Developing new labels and carton artworks for every new customer and getting it delivered on time
- Adjusting the machine settings to do much more than their original purpose
- Optimizing the machine to be capable for obtaining maximum productivity
- Achievements:
- Installation of an entire production line from scratch
- Meeting timelines of dispatch and Production of goods worth 4 million USD a year in the first financial year
- Zero Goods rejection and customer complaints
- Amending the machine by designing new parts to make it compatible with different kind of jars
- Successfully finding root causes and eliminating them in the shortest time
- Hourly bottleneck managements to improve productivity at each station
- Cost Calculation of all the products being manufactured
Assistant Manager in Engineering Products
Hindustan Platinum Pvt Ltd
Pawane
05.2017 - 11.2022
- Manage production of silver grains, kilo bars, good delivery bars, leading a team of 25 members along with the routine production schedules, planning, internal workflows and business needs
- New product development such as producing silver blanks of high purity, hardness and weight using QC tools such as APQP, PPAP for planning production schedules and pilot launch phase.
- Continuous monitoring of production activities, process change and improvisation wherever possible, implementing Kaizens and analyzing the yield after the improvement
- Familiar with concepts of GD&T (Geometrical Dimensioning & Tolerance) and tolerance stack up.
- Overlooking the production of Thermocouple wires as small as diameters of 25 Microns and also analyzing the production difficulties to improve the yield
- Determination of amount of alloying quantity required as per millivolts generated in the multi-meter during wire calibration
- Periodic preparation of control charts followed by PFMEA whenever the process is out of control.
- In-charge of production of silver grains and bars which involves tilting furnaces and tunnel furnaces to produce 1 kilo bars and 30 kg Good delivery bars
- Intending of consumable requirements and other important services as per requirement
- Uploading of DODs and closing GRNs after verification of the goods
- Delegation of cycle based activities like preventive maintenance, Audits like ISO 9001 : 2015, BIS and adhering to safety measures which are required to followed in the plant
- Dealing with vendors for procuring new machines and conducting trials with certain pre-planned agendas and expectations
- Setting up effective SOP Guidelines and flow charts for smooth functioning of the production process after detailed study and research in the quickest time
- Understanding the requirement of the customer and their applications and improvise and stress on Q.C. methods accordingly
- Scaling up of production by improvising i.e. proper allocation of resources
- Precise Material Accounting and reducing scrap to increase the yield
- Periodic update to the Directors, HODs and other concerned departments and MIS
- Assisting other production teams for their various projects
- Extensively worked on the Designing of Carbide pins of Transfer press Machine shop
- Having cross functional meetings and brainstorming sessions for more transparency
- Preparation of BOM and Routing for the support for ERP Soft-wares
- Proactively following up with the Sales team and the planning team to make my team equipped
- Liaising with various cross functioning teams like sales, accounts for various production activities and profit calculations
- Compiling reports of material movement and production status in ERP software and analyzing the metal loss report and other principal factors by creating a histogram and scatter diagram
- Reconciling the stocks of all the production team during monthly stock by getting approvals from respective management
- Running the MRP activity twice a month and releasing Production orders against the work orders and delegation of further activities like issuing of material for production
- Handling departmental documentation as per ISO standards
- Handling any other task entrusted by the Director/top management
- Identifying and evaluating new methods to simplify the existing routine
- Training other members to work in Navision so that team members become more versatile
- Responsible for planning Critical Risk Components
- Achievements:
- Licensed with 6 sigma green and black belt certificates
- Instrumental in Streamlining the Stock management and material movement process through the Navision 2016
- Completely restore and automate a decommissioned ICOP machine (Transfer Press)
- Detailed study of pins and applications probing towards the designing of pins capable of punching with auto centering
- Successfully achieving the desired hardness on the first few trials for precious metals
- Assessment of percentage of Precious metals in each catalytic converters depending upon their models
- Development of new product with the required quality parameters under pressure
- Maintaining a positive work culture with active involvement of all team members
- Design Optimization and Analysis of a Robotic arm At BARC, MUMBAI as the final year project
Plant Supervisor/Mechanical Engineer
Ishwar Cold Storage
Banglore
11.2016 - 05.2017
- Supervising the installation of all the equipment
- Preparing the daily schedules and allocation of labour
- Routine update to the senior authorities
In plant Trainee
Peekay Steel Castings Pvt Ltd
08.2016 - 10.2016
- Gained significant knowledge in the department of Quality Assurance of steel castings
- Understood the application of thermocouple wires during casting.
- Studied about the baking process of the sand moulds and their thermal treatments
Education
BE - MECH
M.U
01.2015
H.S.C -
CBSE
01.2011
S.S.C -
CBSE
01.2009
Skills
- Strategic Planning, Project management, Kaizen, Six Sigma, Microsoft Office, C Programming, Process Optimization and further expedition of automated machines, 7 QC tools, GD&T, Lean Management
Certification
Licensed with 6 sigma green and black belt certificates
Hobbies and Interests
Reading scientific blogs, Social media and MMORPG gaming
Personal Details
- Date of Birth : 1992-11-04
- Place : Mumbai
Timeline
Production Manager
Copiam Consumer Care Pvt Ltd
03.2023 - Current
Assistant Manager in Engineering Products
Hindustan Platinum Pvt Ltd
05.2017 - 11.2022
Plant Supervisor/Mechanical Engineer
Ishwar Cold Storage
11.2016 - 05.2017
In plant Trainee
Peekay Steel Castings Pvt Ltd
08.2016 - 10.2016
BE - MECH
M.U
H.S.C -
CBSE
S.S.C -
CBSE
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