"Lead Project & Process Engineer" specializing in Lean Manufacturing, Process Optimization, and Agile Project Management in the Automotive Industry.
Aktualisiert am 03.12.2024
Profil
Freiberufler / Selbstständiger
Remote-Arbeit
Verfügbar ab: 03.12.2024
Verfügbar zu: 100%
davon vor Ort: 100%
Lean Manufaturing
Project management
Process Engineering
Agile Methodology
Process Optimization
FMEA (PFMEA/DFMEA)
Continuous Improvement
New Product Introduction
Root Cause Analysis
ISO 9001
SQMS
Total Productive Maintenance
Industry 4.0 Compliance
Production & Manufacturing
Engineering Change Management
AutoCAD (2D & 3D)
Risk Management
SAP ERP Systems
Process Line Balancing
Rapid Prototyping
Ergonomics & Burden Assessment
Project Planning
Equipment Maintenance
English
Native/Bilingual
German
Elementary, A1
Hindi
Communicative
Kannada
Muttersprache

Einsatzorte

Einsatzorte

Heilbronn (+500km) Frankfurt am Main (+500km) Munich (+500km) Berlin (+500km) Hamburg (+500km) Bonn (+500km)
Deutschland, Schweiz, Österreich
möglich

Projekte

Projekte

6 years 11 months
2018-01 - now

Greenfield project

Lead Project & Process Engineer
Lead Project & Process Engineer
  • Spearheaded a $297,000 Greenfield project for a new vehicle assembly facility, managing all phases from layout design to final handover while ensuring milestone completion within budget and resource constraints
  • Led full project lifecycles from concept to commissioning, ensuring Industry 4.0 compliance and global quality standards, while maintaining client and executive satisfaction through regular status meetings
  • Introduced cutting-edge process improvements and hybrid applications in manufacturing, leading to a 35% increase in operational efficiency, while managing prototype, pre-production, and validation phases to stabilize assembly operations
  • Achieved cost savings of $21,500 by collaborating with suppliers, optimizing supplier layouts, refining subcontracting strategies, and implementing lean methodologies to reduce waste and improve process workflows
  • Resolved escalated project issues by conducting comprehensive Root Cause Analysis (RCA) and implementing PFMEA, DFMEA, and Value Stream Mapping, reducing project delivery time by 17% and ensuring adherence to manufacturing standards
  • Developed assembly workstations that adhered 100% to assembly protocols, utilizing GSPAS and MODAPTS simulations in a virtual environment to analyze Ergonomics (Burden and Stress) in vehicle assembly, interpret data and enhanced process capabilities by 16% across the critical areas
  • Improved cross-functional collaboration between Toyota and Suzuki design teams, mitigating bottlenecks in Engineering Change Management, boosting production efficiency by 8%, and enhancing the coordination between design and production
  • Proactively identified and mitigated risks throughout process planning, achieved KPI?s by employing Agile methodologies to ensure timely project delivery, enhanced risk management, and a 16% increase in project throughput
Toyota Kirloskar Motors
Bengaluru, India
1 year 4 months
2022-01 - 2023-04

Greenfield Project for Vehicle Assembly Facility

Lead Project & Process Engineer Project management process optimization lean manufacturing ...
Lead Project & Process Engineer
  • Managed all project phases from conceptualization, including design, layout, RFQ, Purchase Request till handover to respective stakeholders.
  • Ensured project compliance with Industry 4.0 and global quality standards.
  • Introduced process improvements that increased operational efficiency by 35%.
  • Collaborated with suppliers to optimize layouts and reduce waste.
  • Conducted Root Cause Analysis (RCA), PFMEA, and DFMEA to resolve project issues and reduce delivery time.
Vehicle assembly facility hybrid manufacturing technologies Hilux Camry Hycross
Project management process optimization lean manufacturing Agile risk management supplier collaboration process improvement.
Toyota Kirloskar Motors
Bengaluru, India
4 years
2015-01 - 2018-12

Remarkable operational efficiency

Operation Engineer
Operation Engineer
  • Achieved a remarkable 98% operational efficiency by standardizing the Standard Work Cycle (SWC) and Standard Work Combination Table (SWCT), significantly reducing process and auxiliary times
  • Enhanced ergonomics and reduced cycle times by 5 seconds through process improvements and Toyota?s Burden Assessment initiative, saving 471 labor hours annually and promoting safer working conditions
  • Automated the Body-In-White (BIW) process using zero-energy equipment, eliminating hazardous waste and increasing efficiency by 100%, aligning operations with Toyota?s sustainability goals
  • Implemented data-driven process adjustments that reduced process variability, optimized workflows, and improved production quality, all contributing to Toyota?s commitment to operational excellence
  • Facilitated continuous improvement initiatives through internal and layered audits, resulting in a 10% increase in overall operational efficiency
  • Manufacturing Execution of Error Proofing System Management, successfully updated and managed data in Total Quality Monitoring & Security system, DC tool upgradation and Production Validation and facilitated smoother process deployment and reduced data entry errors by 27%
Toyota Kirloskar Motors
Bengaluru, India
9 months
2015-05 - 2016-01

Body-In-White (BIW) Process Automation

Operation Engineer Process automation lean manufacturing continuous improvement ...
Operation Engineer
  • Automated the BIW Body wiping process using zero-energy equipment.
  • Improved ergonomics and reduced cycle times by 5 seconds with 2 manpower.
  • Reduced process variability and optimized workflows for better quality.
  • Conducted continuous improvement audits to increase operational efficiency by 10%.
Body-In-White process automation zero-energy equipment
Process automation lean manufacturing continuous improvement data analysis ergonomics.
Toyota Kirloskar Motors
Bangalore, India
4 years
2012-01 - 2015-12

Boosted operational efficiency

Maintenance Engineer
Maintenance Engineer
  • Boosted operational efficiency by 30% by employing the GSBB principles and creating detailed Technical Data Sheets, which led to a 40% reduction in equipment downtime and a more consistent preventive maintenance schedule
  • Reduced preventive maintenance frequencies by 75%, transitioning from 12 annual maintenance sessions to just 3, improving both resource management and machinery uptime
  • Designed and deployed innovative tools, jigs, and fixtures that improved assembly accuracy and reduced setup times by 22%, contributing to smoother production lines
  • Developed a robust maintenance program, increasing process reliability and reducing overall maintenance costs while achieving 100% compliance with Toyota?s quality standards
  • Pioneered the implementation of foolproof systems maintenance, ensuring flawless execution and reducing assembly errors to zero across all production lines
Toyota Kirloskar Motors
Bengaluru, India
7 months
2012-12 - 2013-06

Preventive Maintenance Optimization

Maintenance Engineer Maintenance optimization equipment reliability process improvement ...
Maintenance Engineer
  • Optimized preventive maintenance scheduling, reducing frequencies by 75%.
  • Designed tools, jigs, and fixtures to improve assembly accuracy.
  • Developed a maintenance program to reduce downtime and maintenance costs.
Maintenance tools jigs fixtures preventive maintenance program
Maintenance optimization equipment reliability process improvement tool design
Toyota Kirloskar Motors
Banglore, India

Aus- und Weiterbildung

Aus- und Weiterbildung

3 years
2021-07 - 2024-06

Mechanical Engineering

Bachelor of Technology ? Mechanical Engineering, Birla Institute of Technology and Science, India
Bachelor of Technology ? Mechanical Engineering
Birla Institute of Technology and Science, India

  • Operations & Project Management
  • Production Planning & Control
  • Strategic Management
  • Sustainability
  • Manufacturing Processes
  • Quality Control & Assurance
  • Process Optimisation
  • Failure Mode Analysis
  • Change Management


The Engineering Technology program at BITS Pilani focuses on the application of engineering principles and technology to solve real-world problems in various domains. While the curriculum and focus areas can evolve, key focuses typically include:

Practical Application of Engineering Principles

  • Engineering Technology programs at BITS Pilani are designed to emphasize hands-on learning and practical application. Students work on projects, labs, and industry-driven problems to apply theoretical knowledge.
Industry-Relevant Skills
  • The program is tailored to equip students with skills that are directly applicable in the industry. This includes familiarity with modern tools, technologies, and processes that drive the technological landscape in fields such as manufacturing, automation, software development, and hardware systems.
Interdisciplinary Approach
  • Engineering Technology integrates principles from various branches of engineering (mechanical, electrical, computer science, etc.) to offer a well-rounded understanding. This interdisciplinary approach helps in tackling complex systems and technological challenges.
Innovation and Product Development
  • Students are encouraged to focus on innovation, with the opportunity to engage in product development, prototyping, and the application of emerging technologies. The curriculum includes project-based learning to foster creative problem-solving.
Automation and Robotics
  • Given the current global trends, there is a significant emphasis on automation, robotics, and AI. These areas have applications in manufacturing, process optimization, and even in industries like healthcare and logistics.
Sustainability and Green Technology
  • The curriculum includes sustainable engineering practices, energy efficiency, and the development of eco-friendly technologies, reflecting the growing importance of sustainability in engineering solutions.
Global Exposure and Industry Collaboration
  • BITS Pilani offers students opportunities for internships, industrial collaborations, and exposure to global best practices through its extensive network of industry partners.
Research and Development
  • Students have opportunities to engage in R&D through university projects and collaborations with industry, fostering an environment of continuous learning and innovation.
Entrepreneurship
  • The program encourages students to explore entrepreneurship in the field of technology, with courses and support structures that enable students to develop start-up ideas or work on technology commercialization.

In summary, the Engineering Technology program at BITS Pilani is focused on equipping students with a strong foundation in engineering principles, practical problem-solving skills, and the ability to innovate and apply technology across various domains.

3 years
2009-06 - 2012-05

Mechanical Engineering (Specialization in Welding and Sheetmetal Technology)

Diploma in Mechanical Engineering, Sri Jayachamrajendra Polytechnic, India
Diploma in Mechanical Engineering
Sri Jayachamrajendra Polytechnic, India

The Diploma in Mechanical Engineering at SJ Government Polytechnic, Bangalore, focuses on providing students with a comprehensive understanding of mechanical engineering concepts and practical skills. Here are the key areas of focus:

Core Mechanical Engineering Concepts:
  • Mechanics: Study of forces, motion, and the behavior of materials under different conditions.
  • Thermodynamics: Understanding of heat, energy, and work, and their applications in engines, refrigeration, and air-conditioning.
  • Fluid Mechanics: Study of fluid properties and their applications in pumps, turbines, and hydraulic systems.
  • Strength of Materials: Analysis of the mechanical properties of materials, including stress, strain, and deformation under load.
  • Manufacturing Processes: Techniques such as casting, welding, machining, and material processing to manufacture products.
  • Machine Design: The principles and techniques involved in designing mechanical components and systems, including gears, shafts, bearings, and other mechanical elements.
Practical Skills Development:
  • Hands-on experience through laboratory work and workshops.
  • Use of industry-standard tools and machinery in the workshop.
  • Training in Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) software for designing and simulating mechanical systems.
Materials Science:
  • Study of different materials used in mechanical engineering such as metals, polymers, composites, and their applications.
  • Selection of materials based on their properties for various mechanical components.
Production Technology:
  • Understanding various manufacturing techniques such as machining, casting, forming, and welding.
  • Process planning, cost estimation, and quality control in manufacturing industries.
Automobile Engineering:
  • Introduction to vehicle mechanics, engine working principles, and systems like braking, transmission, and suspension.
Energy Engineering:
  • Focus on renewable and non-renewable energy sources, energy conversion systems, and energy efficiency.
  • Study of thermal and fluid systems like boilers, turbines, and engines.
Project Work & Industrial Training:
  • Students work on projects related to mechanical systems and gain real-world experience.
  • Industrial visits and internships to provide exposure to the latest technologies and practices in the field.
Environmental and Safety Concerns:
  • Focus on sustainable engineering practices, waste reduction, and the environmental impact of mechanical systems.
  • Emphasis on safety in the design, manufacturing, and maintenance of mechanical systems.

The program is designed to ensure that students are equipped with both theoretical knowledge and practical skills necessary for careers in industries like automotive, aerospace, manufacturing, energy, and automation. The curriculum typically combines classroom learning with hands-on practice and industry exposure to ensure students are job-ready upon graduation.

Position

Position

  • I work as a "Lead Project & Process Engineer" in Toyota Kirloskar Motors, the automobile and automotive industry, where I specialize in overseeing engineering projects from start to finish. My role involves managing all aspects of the project lifecycle, starting with the design and layout of production facilities, and continuing through to commissioning and handover. I focus on ensuring that everything meets industry standards while also being completed on time and within budget.
  • My main areas of expertise are process optimization and continuous improvement, where I use tools like Lean manufacturing, Agile, and Six Sigma to eliminate waste, increase efficiency, and drive cost reductions. I?m deeply involved in New Product Introduction (NPI), ensuring that new products are introduced smoothly while meeting all quality and operational standards.
  • Quality is a major focus for me, so I work with ISO standards like ISO 9001 and IATF 16949 to ensure the highest levels of quality and risk management. I also lead initiatives in sustainability, helping to reduce energy use and contributing to carbon-neutral goals.
  • A big part of my job is leading cross-functional teams, making sure that we collaborate well across different departments to meet goals. I also focus on improving production line stability, making processes more efficient, and ensuring safety and ergonomics are always considered in the production process. Overall, my role is all about improving manufacturing processes, driving efficiency, and making sure everything runs smoothly.

Kompetenzen

Kompetenzen

Top-Skills

Lean Manufaturing Project management Process Engineering Agile Methodology Process Optimization FMEA (PFMEA/DFMEA) Continuous Improvement New Product Introduction Root Cause Analysis ISO 9001 SQMS Total Productive Maintenance Industry 4.0 Compliance Production & Manufacturing Engineering Change Management AutoCAD (2D & 3D) Risk Management SAP ERP Systems Process Line Balancing Rapid Prototyping Ergonomics & Burden Assessment Project Planning Equipment Maintenance

Produkte / Standards / Erfahrungen / Methoden

Profile:

Experienced and results-oriented Project and Process Engineer with over 12 years of experience in the automotive industry, leading large-scale engineering projects for top-tier companies. Proven expertise in process optimisation, product development, and driving continuous improvement initiatives. Adept at managing cross-functional teams, ensuring adherence to industry standards, and delivering projects within budget and timelines. Skilled in hybrid manufacturing technologies, risk management, and sustainability practices. A proactive leader with a hands-on approach to enhancing manufacturing efficiency and fostering innovative solutions.

  • Extensive experience in launching complex assembly processes and managing entire project life cycles in Greenfield and Brownfield projects, including design, factory-level layout optimization, and commissioning, strongly focusing on safety, quality, rate, cost, and meeting organizational KPIs.
  • Proficient in FMEA (PFMEA, DFMEA), Safety Risk Assessments, and quality control plans, ensuring adherence to safety standards, compliance with ISO 9001/IATF 16949, and minimizing defects.
  • Proven leadership in driving dimensional improvement plans, GD&T strategies, and quality management systems while collaborating with Design Engineering to streamline manufacturing, enhance flexibility, and ensure world-class production line stability and safety.
  • Demonstrated success in sustainable manufacturing best practices, achieving measurable energy reductions and contributing to carbon-neutral goals.


Tools: 

  • AutoCAD (2D & 3D)
  • SAP-ERP
  • Flexsim
  • Fusion 360
  • ANSYS
  • AFDEX
  • Multisim


Standards & Methodologies: 

  • ISO 9001
  • IATF 16949
  • Industry 4.0
  • Total Productivity Management (TPM)
  • PFMEA
  • DFMEA
  • 5S
  • Kaizen
  • Lean Manufacturing
  • Six Sigma
  • MS Tools


Project Management:

  • Agile
  • Scrum
  • PDCA
  • RCA
  • VSM


Areas of Expertise:

  • Project Management 
  • Process Engineering 
  • New Product Introduction (NPI) 
  • Lean Manufacturing 
  • Total Productive Maintenance
  • Failure Mode and Effects Analysis (FMEA) 
  • Agile and SCRUM 
  • Methodologies 
  • Value Stream Mapping 
  • AutoCAD 2D & 3D 
  • Process Optimisation 
  • Sustainability and Energy Management 
  • Root Cause Analysis (RCA) 
  • Risk Management 
  • Change Management
  • Production Planning & Control 
  • Ergonomics and Burden Assessment 
  • Design for Manufacture and Assembly 
  • SAP ERP System


Industry Expertise:

I am an experienced and results-oriented Project & Process Engineer with over 12+ years of experience in the automotive industry, specializing in process optimization, continuous improvement, and lean manufacturing. Throughout my career, I have led large-scale engineering projects for top-tier companies, ensuring operational excellence while adhering to international quality standards and delivering projects on time and within budget. I have successfully applied my knowledge in hybrid manufacturing technologies, risk management, and sustainability practices, contributing significantly to the success of every project I manage.


Specialized Skills:

  • Lean Manufacturing & Agile Methodologies: I am highly proficient in applying lean manufacturing principles and Agile project management to reduce waste, improve production efficiency, and deliver projects effectively. My experience in managing the full project lifecycle?from design to commissioning?has resulted in a 35% increase in operational efficiency and notable cost savings through process improvement and waste reduction. 
  • Quality Management Systems: With expertise in ISO 9001 and IATF 16949, I ensure that all projects adhere to the highest industry standards. I have successfully implemented quality assurance protocols and led projects that require strict compliance with global quality benchmarks.
  • Sustainability & Energy Management: I am deeply committed to sustainable manufacturing practices, having implemented energy reductions and contributed to carbon-neutral goals across projects. This includes innovative solutions for zero-energy automation and other sustainability initiatives in manufacturing.


Project Experience:

  • Toyota Kirloskar Motors (Lead Project & Process Engineer): I managed a $297,000 Greenfield project for a new vehicle assembly facility, leading all phases from design to final handover while ensuring industry compliance and achieving milestone completion within budget. My leadership in implementing Industry 4.0 technologies and lean methodologies resulted in a 35% increase in operational efficiency and a $21,500 cost saving. Additionally, I successfully mitigated risks and ensured adherence to quality standards by applying PFMEA and DFMEA.
  • Operational Efficiency: At Toyota Kirloskar Motors, I drove significant operational improvements, such as achieving 98% operational efficiency by standardizing workflows and reducing cycle times through ergonomics assessments. My focus on continuous improvement led to a 10% increase in operational efficiency across production lines.


Risk Management & Process Improvements:

With a strong background in risk analysis, failure mode analysis (PFMEA, DFMEA), and Root Cause Analysis (RCA), I am adept at identifying potential risks early and implementing corrective actions to minimize disruptions. For example, by addressing project issues through RCA and Value Stream Mapping, I reduced project delivery time by 17% and improved overall process stability. These efforts have consistently resulted in higher quality, lower risk, and improved production throughput.


Leadership & Cross-Functional Collaboration:

  • I have demonstrated strong leadership in coordinating cross-functional teams to optimize processes and improve production efficiency. By fostering collaboration between Toyota and Suzuki design teams, I successfully mitigated bottlenecks in Engineering Change Management, which boosted production efficiency by 8% and enhanced project coordination between teams.
  • By leveraging my project management skills, process engineering expertise, and dedication to sustainability, I have consistently delivered results that align with both organizational goals and industry standards. My deep knowledge of automotive manufacturing processes and commitment to continuous improvement make me an ideal fit for projects requiring expertise in quality management, lean manufacturing, and operational excellence.

Produktion & Fertigung

Project Management
Experte
Process Engineering
Experte
New Product Introduction (NPI)
Fortgeschritten
Lean Manufacturing
Fortgeschritten
Agile Methodology
Fortgeschritten
Engineering Change Management
Experte
Risk Management
Experte
Quality Assurance
Fortgeschritten
Continuous Improvement
Experte
Failure Mode Analysis (FMEA)
Experte
Root Cause Analysis (RCA)
Experte
Prototyping
Experte
AutoCAD (2D & 3D)
Fortgeschritten
SAP ERP System
Experte
Ergonomics and Burden Assessment
Experte
Total Productive Maintenance (TPM)
Experte
Design for Manufacture & Assembly
Experte
Manufacturing Optimization
Experte
Cross-Functional Collaboration
Experte

My skill set reflects a strong background in project management and process engineering, especially in the automotive and manufacturing sectors. I?m highly experienced in managing complex projects, from initial design all the way through to commissioning, and I focus heavily on optimizing processes to improve efficiency and quality. I have a lot of experience in New Product Introduction (NPI), where I take a product from concept to market, ensuring everything runs smoothly and efficiently. This is particularly important in fast-paced industries like automotive.

I also specialize in Lean Manufacturing and Six Sigma, which are methodologies that focus on reducing waste and improving production efficiency. These are critical to keeping operations cost-effective and running smoothly. On top of that, I apply Agile Methodology in managing projects, which helps me stay flexible and adapt quickly, especially when things change or new challenges arise.

In terms of quality assurance, I?m well-versed in working with ISO standards like ISO 9001 and IATF 16949, which ensures that everything I work on meets the highest industry standards. I also have a solid background in Risk Management, especially using tools like FMEA (Failure Modes and Effects Analysis) to identify potential issues before they become problems. I make sure that quality and compliance are maintained at all times, and I do this by implementing structured methods for evaluating risks and solving problems.

Another area I focus on is sustainability and energy management. This is important not only for improving efficiency but also for contributing to environmental goals. I?ve led initiatives that have helped reduce energy consumption and waste, which is a big priority in today's manufacturing landscape.

I also use Root Cause Analysis (RCA) to investigate and solve problems, which is really helpful in identifying the exact cause of an issue so we can fix it properly. I handle Change Management too, helping teams adapt to changes smoothly, whether that?s new technologies, processes, or team structures.

I pride myself on my ability to lead and collaborate with cross-functional teams. It's crucial to work well with different departments?like engineering, production, and design?to ensure everyone is aligned and working towards the same goals. This collaboration is key to overcoming challenges and ensuring a project?s success.

In terms of technical skills, I?m proficient in tools like AutoCAD, SAP ERP, and ANSYS. These are essential for designing and managing projects in a technical environment, and I use them to optimize everything from product design to production workflows.

Finally, I?ve got expertise in ergonomics and Design for Manufacture. I focus on creating workspaces and processes that are not only efficient but also safe and comfortable for workers. This helps reduce cycle times and improves overall production quality

Strengths:

  • I?ve got a broad range of skills, from leading projects to optimizing processes, and I have a hands-on approach to improving operational efficiency.
  • My knowledge of industry standards and methodologies like Lean, Six Sigma, and Agile allows me to drive results and reduce costs effectively.
  • I?m also a strong leader and know how to work with different teams to achieve common goals, which makes me a valuable asset to any project.

Areas to Improve:

  • I?m still learning German, so I can improve my language skills to better communicate in German-speaking environments.
  • While I?m strong in project and process management, I could expand my knowledge in strategic management at a higher level, like supply chain optimization or business strategy, which would prepare me for even more senior roles in the future.

Branchen

Branchen


Einsatzorte

Einsatzorte

Heilbronn (+500km) Frankfurt am Main (+500km) Munich (+500km) Berlin (+500km) Hamburg (+500km) Bonn (+500km)
Deutschland, Schweiz, Österreich
möglich

Projekte

Projekte

6 years 11 months
2018-01 - now

Greenfield project

Lead Project & Process Engineer
Lead Project & Process Engineer
  • Spearheaded a $297,000 Greenfield project for a new vehicle assembly facility, managing all phases from layout design to final handover while ensuring milestone completion within budget and resource constraints
  • Led full project lifecycles from concept to commissioning, ensuring Industry 4.0 compliance and global quality standards, while maintaining client and executive satisfaction through regular status meetings
  • Introduced cutting-edge process improvements and hybrid applications in manufacturing, leading to a 35% increase in operational efficiency, while managing prototype, pre-production, and validation phases to stabilize assembly operations
  • Achieved cost savings of $21,500 by collaborating with suppliers, optimizing supplier layouts, refining subcontracting strategies, and implementing lean methodologies to reduce waste and improve process workflows
  • Resolved escalated project issues by conducting comprehensive Root Cause Analysis (RCA) and implementing PFMEA, DFMEA, and Value Stream Mapping, reducing project delivery time by 17% and ensuring adherence to manufacturing standards
  • Developed assembly workstations that adhered 100% to assembly protocols, utilizing GSPAS and MODAPTS simulations in a virtual environment to analyze Ergonomics (Burden and Stress) in vehicle assembly, interpret data and enhanced process capabilities by 16% across the critical areas
  • Improved cross-functional collaboration between Toyota and Suzuki design teams, mitigating bottlenecks in Engineering Change Management, boosting production efficiency by 8%, and enhancing the coordination between design and production
  • Proactively identified and mitigated risks throughout process planning, achieved KPI?s by employing Agile methodologies to ensure timely project delivery, enhanced risk management, and a 16% increase in project throughput
Toyota Kirloskar Motors
Bengaluru, India
1 year 4 months
2022-01 - 2023-04

Greenfield Project for Vehicle Assembly Facility

Lead Project & Process Engineer Project management process optimization lean manufacturing ...
Lead Project & Process Engineer
  • Managed all project phases from conceptualization, including design, layout, RFQ, Purchase Request till handover to respective stakeholders.
  • Ensured project compliance with Industry 4.0 and global quality standards.
  • Introduced process improvements that increased operational efficiency by 35%.
  • Collaborated with suppliers to optimize layouts and reduce waste.
  • Conducted Root Cause Analysis (RCA), PFMEA, and DFMEA to resolve project issues and reduce delivery time.
Vehicle assembly facility hybrid manufacturing technologies Hilux Camry Hycross
Project management process optimization lean manufacturing Agile risk management supplier collaboration process improvement.
Toyota Kirloskar Motors
Bengaluru, India
4 years
2015-01 - 2018-12

Remarkable operational efficiency

Operation Engineer
Operation Engineer
  • Achieved a remarkable 98% operational efficiency by standardizing the Standard Work Cycle (SWC) and Standard Work Combination Table (SWCT), significantly reducing process and auxiliary times
  • Enhanced ergonomics and reduced cycle times by 5 seconds through process improvements and Toyota?s Burden Assessment initiative, saving 471 labor hours annually and promoting safer working conditions
  • Automated the Body-In-White (BIW) process using zero-energy equipment, eliminating hazardous waste and increasing efficiency by 100%, aligning operations with Toyota?s sustainability goals
  • Implemented data-driven process adjustments that reduced process variability, optimized workflows, and improved production quality, all contributing to Toyota?s commitment to operational excellence
  • Facilitated continuous improvement initiatives through internal and layered audits, resulting in a 10% increase in overall operational efficiency
  • Manufacturing Execution of Error Proofing System Management, successfully updated and managed data in Total Quality Monitoring & Security system, DC tool upgradation and Production Validation and facilitated smoother process deployment and reduced data entry errors by 27%
Toyota Kirloskar Motors
Bengaluru, India
9 months
2015-05 - 2016-01

Body-In-White (BIW) Process Automation

Operation Engineer Process automation lean manufacturing continuous improvement ...
Operation Engineer
  • Automated the BIW Body wiping process using zero-energy equipment.
  • Improved ergonomics and reduced cycle times by 5 seconds with 2 manpower.
  • Reduced process variability and optimized workflows for better quality.
  • Conducted continuous improvement audits to increase operational efficiency by 10%.
Body-In-White process automation zero-energy equipment
Process automation lean manufacturing continuous improvement data analysis ergonomics.
Toyota Kirloskar Motors
Bangalore, India
4 years
2012-01 - 2015-12

Boosted operational efficiency

Maintenance Engineer
Maintenance Engineer
  • Boosted operational efficiency by 30% by employing the GSBB principles and creating detailed Technical Data Sheets, which led to a 40% reduction in equipment downtime and a more consistent preventive maintenance schedule
  • Reduced preventive maintenance frequencies by 75%, transitioning from 12 annual maintenance sessions to just 3, improving both resource management and machinery uptime
  • Designed and deployed innovative tools, jigs, and fixtures that improved assembly accuracy and reduced setup times by 22%, contributing to smoother production lines
  • Developed a robust maintenance program, increasing process reliability and reducing overall maintenance costs while achieving 100% compliance with Toyota?s quality standards
  • Pioneered the implementation of foolproof systems maintenance, ensuring flawless execution and reducing assembly errors to zero across all production lines
Toyota Kirloskar Motors
Bengaluru, India
7 months
2012-12 - 2013-06

Preventive Maintenance Optimization

Maintenance Engineer Maintenance optimization equipment reliability process improvement ...
Maintenance Engineer
  • Optimized preventive maintenance scheduling, reducing frequencies by 75%.
  • Designed tools, jigs, and fixtures to improve assembly accuracy.
  • Developed a maintenance program to reduce downtime and maintenance costs.
Maintenance tools jigs fixtures preventive maintenance program
Maintenance optimization equipment reliability process improvement tool design
Toyota Kirloskar Motors
Banglore, India

Aus- und Weiterbildung

Aus- und Weiterbildung

3 years
2021-07 - 2024-06

Mechanical Engineering

Bachelor of Technology ? Mechanical Engineering, Birla Institute of Technology and Science, India
Bachelor of Technology ? Mechanical Engineering
Birla Institute of Technology and Science, India

  • Operations & Project Management
  • Production Planning & Control
  • Strategic Management
  • Sustainability
  • Manufacturing Processes
  • Quality Control & Assurance
  • Process Optimisation
  • Failure Mode Analysis
  • Change Management


The Engineering Technology program at BITS Pilani focuses on the application of engineering principles and technology to solve real-world problems in various domains. While the curriculum and focus areas can evolve, key focuses typically include:

Practical Application of Engineering Principles

  • Engineering Technology programs at BITS Pilani are designed to emphasize hands-on learning and practical application. Students work on projects, labs, and industry-driven problems to apply theoretical knowledge.
Industry-Relevant Skills
  • The program is tailored to equip students with skills that are directly applicable in the industry. This includes familiarity with modern tools, technologies, and processes that drive the technological landscape in fields such as manufacturing, automation, software development, and hardware systems.
Interdisciplinary Approach
  • Engineering Technology integrates principles from various branches of engineering (mechanical, electrical, computer science, etc.) to offer a well-rounded understanding. This interdisciplinary approach helps in tackling complex systems and technological challenges.
Innovation and Product Development
  • Students are encouraged to focus on innovation, with the opportunity to engage in product development, prototyping, and the application of emerging technologies. The curriculum includes project-based learning to foster creative problem-solving.
Automation and Robotics
  • Given the current global trends, there is a significant emphasis on automation, robotics, and AI. These areas have applications in manufacturing, process optimization, and even in industries like healthcare and logistics.
Sustainability and Green Technology
  • The curriculum includes sustainable engineering practices, energy efficiency, and the development of eco-friendly technologies, reflecting the growing importance of sustainability in engineering solutions.
Global Exposure and Industry Collaboration
  • BITS Pilani offers students opportunities for internships, industrial collaborations, and exposure to global best practices through its extensive network of industry partners.
Research and Development
  • Students have opportunities to engage in R&D through university projects and collaborations with industry, fostering an environment of continuous learning and innovation.
Entrepreneurship
  • The program encourages students to explore entrepreneurship in the field of technology, with courses and support structures that enable students to develop start-up ideas or work on technology commercialization.

In summary, the Engineering Technology program at BITS Pilani is focused on equipping students with a strong foundation in engineering principles, practical problem-solving skills, and the ability to innovate and apply technology across various domains.

3 years
2009-06 - 2012-05

Mechanical Engineering (Specialization in Welding and Sheetmetal Technology)

Diploma in Mechanical Engineering, Sri Jayachamrajendra Polytechnic, India
Diploma in Mechanical Engineering
Sri Jayachamrajendra Polytechnic, India

The Diploma in Mechanical Engineering at SJ Government Polytechnic, Bangalore, focuses on providing students with a comprehensive understanding of mechanical engineering concepts and practical skills. Here are the key areas of focus:

Core Mechanical Engineering Concepts:
  • Mechanics: Study of forces, motion, and the behavior of materials under different conditions.
  • Thermodynamics: Understanding of heat, energy, and work, and their applications in engines, refrigeration, and air-conditioning.
  • Fluid Mechanics: Study of fluid properties and their applications in pumps, turbines, and hydraulic systems.
  • Strength of Materials: Analysis of the mechanical properties of materials, including stress, strain, and deformation under load.
  • Manufacturing Processes: Techniques such as casting, welding, machining, and material processing to manufacture products.
  • Machine Design: The principles and techniques involved in designing mechanical components and systems, including gears, shafts, bearings, and other mechanical elements.
Practical Skills Development:
  • Hands-on experience through laboratory work and workshops.
  • Use of industry-standard tools and machinery in the workshop.
  • Training in Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) software for designing and simulating mechanical systems.
Materials Science:
  • Study of different materials used in mechanical engineering such as metals, polymers, composites, and their applications.
  • Selection of materials based on their properties for various mechanical components.
Production Technology:
  • Understanding various manufacturing techniques such as machining, casting, forming, and welding.
  • Process planning, cost estimation, and quality control in manufacturing industries.
Automobile Engineering:
  • Introduction to vehicle mechanics, engine working principles, and systems like braking, transmission, and suspension.
Energy Engineering:
  • Focus on renewable and non-renewable energy sources, energy conversion systems, and energy efficiency.
  • Study of thermal and fluid systems like boilers, turbines, and engines.
Project Work & Industrial Training:
  • Students work on projects related to mechanical systems and gain real-world experience.
  • Industrial visits and internships to provide exposure to the latest technologies and practices in the field.
Environmental and Safety Concerns:
  • Focus on sustainable engineering practices, waste reduction, and the environmental impact of mechanical systems.
  • Emphasis on safety in the design, manufacturing, and maintenance of mechanical systems.

The program is designed to ensure that students are equipped with both theoretical knowledge and practical skills necessary for careers in industries like automotive, aerospace, manufacturing, energy, and automation. The curriculum typically combines classroom learning with hands-on practice and industry exposure to ensure students are job-ready upon graduation.

Position

Position

  • I work as a "Lead Project & Process Engineer" in Toyota Kirloskar Motors, the automobile and automotive industry, where I specialize in overseeing engineering projects from start to finish. My role involves managing all aspects of the project lifecycle, starting with the design and layout of production facilities, and continuing through to commissioning and handover. I focus on ensuring that everything meets industry standards while also being completed on time and within budget.
  • My main areas of expertise are process optimization and continuous improvement, where I use tools like Lean manufacturing, Agile, and Six Sigma to eliminate waste, increase efficiency, and drive cost reductions. I?m deeply involved in New Product Introduction (NPI), ensuring that new products are introduced smoothly while meeting all quality and operational standards.
  • Quality is a major focus for me, so I work with ISO standards like ISO 9001 and IATF 16949 to ensure the highest levels of quality and risk management. I also lead initiatives in sustainability, helping to reduce energy use and contributing to carbon-neutral goals.
  • A big part of my job is leading cross-functional teams, making sure that we collaborate well across different departments to meet goals. I also focus on improving production line stability, making processes more efficient, and ensuring safety and ergonomics are always considered in the production process. Overall, my role is all about improving manufacturing processes, driving efficiency, and making sure everything runs smoothly.

Kompetenzen

Kompetenzen

Top-Skills

Lean Manufaturing Project management Process Engineering Agile Methodology Process Optimization FMEA (PFMEA/DFMEA) Continuous Improvement New Product Introduction Root Cause Analysis ISO 9001 SQMS Total Productive Maintenance Industry 4.0 Compliance Production & Manufacturing Engineering Change Management AutoCAD (2D & 3D) Risk Management SAP ERP Systems Process Line Balancing Rapid Prototyping Ergonomics & Burden Assessment Project Planning Equipment Maintenance

Produkte / Standards / Erfahrungen / Methoden

Profile:

Experienced and results-oriented Project and Process Engineer with over 12 years of experience in the automotive industry, leading large-scale engineering projects for top-tier companies. Proven expertise in process optimisation, product development, and driving continuous improvement initiatives. Adept at managing cross-functional teams, ensuring adherence to industry standards, and delivering projects within budget and timelines. Skilled in hybrid manufacturing technologies, risk management, and sustainability practices. A proactive leader with a hands-on approach to enhancing manufacturing efficiency and fostering innovative solutions.

  • Extensive experience in launching complex assembly processes and managing entire project life cycles in Greenfield and Brownfield projects, including design, factory-level layout optimization, and commissioning, strongly focusing on safety, quality, rate, cost, and meeting organizational KPIs.
  • Proficient in FMEA (PFMEA, DFMEA), Safety Risk Assessments, and quality control plans, ensuring adherence to safety standards, compliance with ISO 9001/IATF 16949, and minimizing defects.
  • Proven leadership in driving dimensional improvement plans, GD&T strategies, and quality management systems while collaborating with Design Engineering to streamline manufacturing, enhance flexibility, and ensure world-class production line stability and safety.
  • Demonstrated success in sustainable manufacturing best practices, achieving measurable energy reductions and contributing to carbon-neutral goals.


Tools: 

  • AutoCAD (2D & 3D)
  • SAP-ERP
  • Flexsim
  • Fusion 360
  • ANSYS
  • AFDEX
  • Multisim


Standards & Methodologies: 

  • ISO 9001
  • IATF 16949
  • Industry 4.0
  • Total Productivity Management (TPM)
  • PFMEA
  • DFMEA
  • 5S
  • Kaizen
  • Lean Manufacturing
  • Six Sigma
  • MS Tools


Project Management:

  • Agile
  • Scrum
  • PDCA
  • RCA
  • VSM


Areas of Expertise:

  • Project Management 
  • Process Engineering 
  • New Product Introduction (NPI) 
  • Lean Manufacturing 
  • Total Productive Maintenance
  • Failure Mode and Effects Analysis (FMEA) 
  • Agile and SCRUM 
  • Methodologies 
  • Value Stream Mapping 
  • AutoCAD 2D & 3D 
  • Process Optimisation 
  • Sustainability and Energy Management 
  • Root Cause Analysis (RCA) 
  • Risk Management 
  • Change Management
  • Production Planning & Control 
  • Ergonomics and Burden Assessment 
  • Design for Manufacture and Assembly 
  • SAP ERP System


Industry Expertise:

I am an experienced and results-oriented Project & Process Engineer with over 12+ years of experience in the automotive industry, specializing in process optimization, continuous improvement, and lean manufacturing. Throughout my career, I have led large-scale engineering projects for top-tier companies, ensuring operational excellence while adhering to international quality standards and delivering projects on time and within budget. I have successfully applied my knowledge in hybrid manufacturing technologies, risk management, and sustainability practices, contributing significantly to the success of every project I manage.


Specialized Skills:

  • Lean Manufacturing & Agile Methodologies: I am highly proficient in applying lean manufacturing principles and Agile project management to reduce waste, improve production efficiency, and deliver projects effectively. My experience in managing the full project lifecycle?from design to commissioning?has resulted in a 35% increase in operational efficiency and notable cost savings through process improvement and waste reduction. 
  • Quality Management Systems: With expertise in ISO 9001 and IATF 16949, I ensure that all projects adhere to the highest industry standards. I have successfully implemented quality assurance protocols and led projects that require strict compliance with global quality benchmarks.
  • Sustainability & Energy Management: I am deeply committed to sustainable manufacturing practices, having implemented energy reductions and contributed to carbon-neutral goals across projects. This includes innovative solutions for zero-energy automation and other sustainability initiatives in manufacturing.


Project Experience:

  • Toyota Kirloskar Motors (Lead Project & Process Engineer): I managed a $297,000 Greenfield project for a new vehicle assembly facility, leading all phases from design to final handover while ensuring industry compliance and achieving milestone completion within budget. My leadership in implementing Industry 4.0 technologies and lean methodologies resulted in a 35% increase in operational efficiency and a $21,500 cost saving. Additionally, I successfully mitigated risks and ensured adherence to quality standards by applying PFMEA and DFMEA.
  • Operational Efficiency: At Toyota Kirloskar Motors, I drove significant operational improvements, such as achieving 98% operational efficiency by standardizing workflows and reducing cycle times through ergonomics assessments. My focus on continuous improvement led to a 10% increase in operational efficiency across production lines.


Risk Management & Process Improvements:

With a strong background in risk analysis, failure mode analysis (PFMEA, DFMEA), and Root Cause Analysis (RCA), I am adept at identifying potential risks early and implementing corrective actions to minimize disruptions. For example, by addressing project issues through RCA and Value Stream Mapping, I reduced project delivery time by 17% and improved overall process stability. These efforts have consistently resulted in higher quality, lower risk, and improved production throughput.


Leadership & Cross-Functional Collaboration:

  • I have demonstrated strong leadership in coordinating cross-functional teams to optimize processes and improve production efficiency. By fostering collaboration between Toyota and Suzuki design teams, I successfully mitigated bottlenecks in Engineering Change Management, which boosted production efficiency by 8% and enhanced project coordination between teams.
  • By leveraging my project management skills, process engineering expertise, and dedication to sustainability, I have consistently delivered results that align with both organizational goals and industry standards. My deep knowledge of automotive manufacturing processes and commitment to continuous improvement make me an ideal fit for projects requiring expertise in quality management, lean manufacturing, and operational excellence.

Produktion & Fertigung

Project Management
Experte
Process Engineering
Experte
New Product Introduction (NPI)
Fortgeschritten
Lean Manufacturing
Fortgeschritten
Agile Methodology
Fortgeschritten
Engineering Change Management
Experte
Risk Management
Experte
Quality Assurance
Fortgeschritten
Continuous Improvement
Experte
Failure Mode Analysis (FMEA)
Experte
Root Cause Analysis (RCA)
Experte
Prototyping
Experte
AutoCAD (2D & 3D)
Fortgeschritten
SAP ERP System
Experte
Ergonomics and Burden Assessment
Experte
Total Productive Maintenance (TPM)
Experte
Design for Manufacture & Assembly
Experte
Manufacturing Optimization
Experte
Cross-Functional Collaboration
Experte

My skill set reflects a strong background in project management and process engineering, especially in the automotive and manufacturing sectors. I?m highly experienced in managing complex projects, from initial design all the way through to commissioning, and I focus heavily on optimizing processes to improve efficiency and quality. I have a lot of experience in New Product Introduction (NPI), where I take a product from concept to market, ensuring everything runs smoothly and efficiently. This is particularly important in fast-paced industries like automotive.

I also specialize in Lean Manufacturing and Six Sigma, which are methodologies that focus on reducing waste and improving production efficiency. These are critical to keeping operations cost-effective and running smoothly. On top of that, I apply Agile Methodology in managing projects, which helps me stay flexible and adapt quickly, especially when things change or new challenges arise.

In terms of quality assurance, I?m well-versed in working with ISO standards like ISO 9001 and IATF 16949, which ensures that everything I work on meets the highest industry standards. I also have a solid background in Risk Management, especially using tools like FMEA (Failure Modes and Effects Analysis) to identify potential issues before they become problems. I make sure that quality and compliance are maintained at all times, and I do this by implementing structured methods for evaluating risks and solving problems.

Another area I focus on is sustainability and energy management. This is important not only for improving efficiency but also for contributing to environmental goals. I?ve led initiatives that have helped reduce energy consumption and waste, which is a big priority in today's manufacturing landscape.

I also use Root Cause Analysis (RCA) to investigate and solve problems, which is really helpful in identifying the exact cause of an issue so we can fix it properly. I handle Change Management too, helping teams adapt to changes smoothly, whether that?s new technologies, processes, or team structures.

I pride myself on my ability to lead and collaborate with cross-functional teams. It's crucial to work well with different departments?like engineering, production, and design?to ensure everyone is aligned and working towards the same goals. This collaboration is key to overcoming challenges and ensuring a project?s success.

In terms of technical skills, I?m proficient in tools like AutoCAD, SAP ERP, and ANSYS. These are essential for designing and managing projects in a technical environment, and I use them to optimize everything from product design to production workflows.

Finally, I?ve got expertise in ergonomics and Design for Manufacture. I focus on creating workspaces and processes that are not only efficient but also safe and comfortable for workers. This helps reduce cycle times and improves overall production quality

Strengths:

  • I?ve got a broad range of skills, from leading projects to optimizing processes, and I have a hands-on approach to improving operational efficiency.
  • My knowledge of industry standards and methodologies like Lean, Six Sigma, and Agile allows me to drive results and reduce costs effectively.
  • I?m also a strong leader and know how to work with different teams to achieve common goals, which makes me a valuable asset to any project.

Areas to Improve:

  • I?m still learning German, so I can improve my language skills to better communicate in German-speaking environments.
  • While I?m strong in project and process management, I could expand my knowledge in strategic management at a higher level, like supply chain optimization or business strategy, which would prepare me for even more senior roles in the future.

Branchen

Branchen


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