Program Manager

• Oct 2021 - Present

Manager - Manufacturing

• Aug 2017 - Mar 2021

● Managed multiple projects, scheduling and prioritizing to ensure alignment to production targets, and mock-ups development and new product launch schedules ● Attended annual business plans and strategy meetings and proposed new and innovative ideas for improving sales and inventory optimization ● Ensured optimal utilization of resources, and identifying need to add new machines or processes ● Spearheaded the QMS (ISO 9001:2018, 5S, TPM) implementation and sustenance ● Managed annual budgeting of process consumables, training, and new equipment for shop floor ● Ensured quality and delivery of sub-contracted processes by resolving issues ● Conducted regular quality Gemba meetings for in-house processes, root cause analysis through 8D methodology, 5 Why, fishbone diagram, brainstorming and idea generation, design of experiments methodology to select appropriate corrective and preventive actions based on facts/data. ● Managed daily production logs, monthly reports of plan vs. actual, quality performance, COPQ, OEE, MTBF and MTTR, created a database for defects recording, to analyze and predict failure modes and mitigate the risk to production ● Led a team of 80 employees (direct + matrix), and identified training needs for employee development through quarterly performance appraisal meetings ● Collaborated with design, marketing, merchandising teams for manufacturing feasibility for new products ● Ensured compliance to Governance and Factory safety requirements as Safety Committee Chairman ● Ensured compliance, training of employees, resolving issues/conflicts, investigating, and recommending actions based on facts as Local Ethics Counsellor, and Local Complaints Committee Counsellor ● Developed a excel template to create a database for daily production log and defect recording, also automated the SAP (ERP) production order confirmation process by collaborating with SAP programmers, resulted in reduction of non-value-added activities (NVA's) by 10% Show less

Manager - Tool Engineering

• May 2013 - Aug 2017

● Supervised a team of engineers in process and tool design for multiple projects of manufacturing detail parts and sub-assemblies of passenger aircrafts for both FAI & production run ● Led implementation of AS9100C requirements for Tool engineering, new process development, Configuration, and change management ● Implemented Lean practice tools like 5S, Poka-Yoke, Kanban, Visual, and Concurrent Engineering. ● Led process efficiency improvement activities through improved tooling, process simplifications, de-skilling of complex processes and eliminating non-value adding activities ● Proposed changes and updated the QMS manual for Tool engineering in line with AS9100 C requirements as part of knowledge sharing program (Jun, 2014 – Jul, 2014) at Intec Air, Cadiz, Spain (An Aeronova Company) ● Managing and maintaining PP, PM module and databases in ERP systems as SAP super user ● Coordinated NC analysis through various techniques like 5WHY, Cause and Effect Diagram, Brainstorming, Root Cause Analysis and interacting with client for NC closures and FAIR approvals. ● Mentored new recruits on Tool Design, drafting standards, GD&T, best shop practices and QMS ● Supported estimation team with Cost estimation and process feasibility on RFQ’s, evaluated and proofread RFQ documents to evaluate risks and proposed strategies for project risk management and new program development Show less

AM- Process Improvements

• Jun 2012 - Apr 2013

● Handled process improvement activities in sheet metal shop, involving rubber hydro forming, roll forming, CNC routing (3 & 5 Axis), nibbling, hand forming, and alkaline chemical milling of Al alloys. ● Managed and mentored the cross-functional teams through structured analysis of the issues ● Proposed solutions for technical issues in production processes through detailed analysis of the available standards and procedures and collaborating with clients and SMEs across the globe ● Coordinated the Turn-backs analysis through various techniques like 5WHY, Cause and Effect Diagram, Brainstorming, and Relentless Root Cause Analysis Show less

Manager - Tool Design

• Aug 2010 - May 2012

● Ensured tools maintenance and sheet metal parts production of all projects ● Managed tool try-outs and validation, tool assembly, first article prove out, and modification of tools based on trial feedback ● Supervised sheet metal shop team, resource planning, allocation, and review of tool designs ● Collaborated with vendors to extend technical guidance to ensure timely tool delivery with reduced cost ● Coordinated with internal departments during project execution to provide necessary inputs through cross-functional team reviews ● Implemented TPM principles in sheet metal shop and tool design office as Zonal coordinator of JH and KK pillars, also recognized as Safety Champion for the bay ● Managed special improvement projects, AS9100, OHSAS and 5S activities Show less

Senior Executive - Tool Design

• Jan 2006 - Jul 2010

● Prepared new tool designs, modifications and retrofitting of existing designs to achieve better productivity and quality ● Conducted design reviews with internal departments (Process Planning, CAM, Machine Shop, Assembly, Production Planning and control) to validate concept design ● Conducted design reviews with customer to validate and approve the final design ● Managed estimation and rationalization of the manufacturing cost of the tools and fixtures ● Prepared new tool designs, modifications and retrofitting of existing designs to achieve better productivity and quality ● Conducted design reviews with internal departments (Process Planning, CAM, Machine Shop, Assembly, Production Planning and control) to validate concept design ● Conducted design reviews with customer to validate and approve the final design ● Managed estimation and rationalization of the manufacturing cost of the tools and fixtures