Feb 2007 – Mar 2010 · 3 yrs 1 mo · Coimbatore

• Larsen & Toubro is a leading manufacturer of fuel dispenser in India and the facility has capacity of 30,000 hoses per annum. L&T’s PDP business unit manufactures, sells, integrates and services petroleum dispensers, LPG equipment, and automation systems solutions.
• Handling Manufacturing and Customer Quality
• 1) Inspection Lead Time reduction from 5 days to 1 day for GRN clearance achieved through single flow concept
• 2) Payment collection time reduction from customers from 90 days to 40 days by driven through standard work process
• 3) Effective implementation of MRB process in factory for reducing the rejections inventory from 5000K INR to 50K INR within 2 year’s time - Awarded by L&T
• 4) Improved the First Pass Yield from 45% to 95% which resulted in additional Revenue of 50Cr in 2002
• 5) Resolved the critical quality issue of key failures in meters due to hydrogen de-embrittlement process using metallurgical expertise which resulted in tapping of new product business worth of 50Cr in 2009
• 6) 10% of Factory Inventory and Inward Inspection lead time reduction through Green Channel Implementation
• 7) ZERO late delivery penalties with 100% OTD from 2Cr late delivery penalty in 2011 (consistently from 2012 onwards) by implementing DMS using JIT, Dynamic Kanban system and Milk Run system

Feb 2006 – Mar 2007 · 1 yr 1 mo · Coimbatore Area, India

• ELGI Electric is one of the leading manufacturers of industrial and agriculture pumps in India
• Handling Manufacturing Engineering and Quality Systems Implementation
• 1) Introduced Single source calibration across factory include both domestic and export plant which resulted in saved 2 lakhs in a month
• 2) Reduced in-house rejection rate to 5% from 62% after introduced the Layout Inspection at supplier’s place
• 3) Prevention and Detection Poka Yoke implemented in export product assembly which resulted in reduce the in-house rejection rate to 2% from 67% within 2 year’s time
• 4) Tools & Fixtures audit implemented across the plant which resulted in zero break down in the assembly line and Modelcell concept introduced in export product assembly line
• 5) Printing on cables implemented in the cable assembly line instead of pasting the identification stickers on each cable resulted in cost saved 50 lakhs / Annum and brought down the customer complaint to Zero for sticker fallen issue
• 6) Maintained IS 9283 and IS 8034 certificates for submersible pumps and no single non-conformity raised by BIS (Bureau of India Standard) during factory audit
• 7) Cycle time reduction at machining process on motor cover resulted in productivity increased to 800Nos/3 shifts from 620Nos/3 Shifts
• 8) Successfully resolved the motor failure for key comeout issue from shaft which resulted in ramping up of the motor production from 75Nos/shift to 150Nos/shift resulted in sales turnover by 1cr
• 9) Developed leak testing fixtures for all critical parts and new product developments
• 10) Andon system (SIREN) implemented in shopfloor to understand the line stoppages and actions

Jan 2004 – Feb 2006 · 2 yrs 1 mo · Coimbatore Area, India

Jan 2002 – Jan 2004 · 2 yrs · Coimbatore Area, India