P H A N I K U M A R P U P P A L A

Flat No: 1, Samrudha Residency Apartment,Behind Day Care School, Ramnagar, Near Indiranagar,Nasik-422 009, MaharashtraEMAIL id: PUPPALA4U@GMAIL.COM, PUPPALA.PHANI@GMAIL.COMMobile No: 9765567187, 9545888129

EDUCATION QUALIFICATION

MBA Specialization in Finance Management from Assam Down Town University, during 2012-2014 with 72% (First Class).

Post Graduate Diploma in Business Administration (PGDBA) in Specialization in Finance Management from MIT, Pune during 2012-2014 with 72% (First Class).

“Six Sigma Green Belt” and “Lean Six Sigma” Certified

Post Graduate Diploma in Business Administration (PGDBA), Specialization in Operation Management from Symbiosis, Pune during 2007-2009 with 67 %( First Class).

Bachelor of Technology in Mechanical Engineering from Jawaharlal Nehru Technological University Campus College of Engineering, Hyderabad during 2002-2006 with 77.19%.

KEY SKILLS

* Lean Manufacturing * Kaizen, 5S, VSM, Standard Work, Lean Flow

* Rapid Improvement Event * 8D, 7 QC tools

* New Product Development * APQP, PPAP, FMEA, Control plan, SOP

* Project Management * Change Management (ADKAR)

* Six Sigma Green Belt * Lean Six Sigma

* Total Quality Management * SAP PP Module activities

* Industrial Engineering * Time Study & Work measurement

* Capacity calculation & Line balancing * Design and optimizing floor layout.

* Manufacturing Process design * Good communication & presentation skills

* Continuous improvements through Lean Culture*Feasibility Study

SOFTWARE SKILLSOperation systems : Windows 98/2000/XP./VISTA/Windows 8Packages : Micro soft Project, MS-office, Power Point & word

AUTO CAD 2002, ERP (SAP)

AREAS OF EXPERTISE

New Product Development Overall New product Development various activities from RFQ to Process design, Tooling

design, Sample development, machine procurement up to productionisation by smooth handover to Production and continual improvement with Documentation. Flawless Launch ensures by using APQP approach and Preparation of PPAP documentation. Implementing effective techniques across the shop floor to bring efficiency in operations improve quality & safety standards & achieve maximum cost savings.

Continuous Improvement Overall Lean culture Implementation activities, implementing effective techniques like Daily

accountability, Leader’s standard work, Visual standards across the shop floor to bring efficiency in operations, improve quality & safety standards & achieve maximum cost savings. Designing and implementing systems, processes and procedures to facilitate smooth functioning of overall Production activities.

Industrial Engineering Creation of Standards by using on Time study & work measurement techniques. Production

standards, Creating the New Production Lines, Optimizing products in existing Production lines, Plant Layout Creation and Optimization, Operator Balance sheet, Man Power Optimization. Expert in Line balancing & capacity calculation of plant by doing Time study & work measurement methods.

Quality Management Participating in developing and implementing stringent systems and processes for:

-Defect detection, Poka Yoke, 8D, 7 QC tools, corrective action and defect prevention, ensuring high quality standards.

Change Management Implementation of People side Change through ADKAR Model.

PROFESSIONAL EXPERIENCE

SUMMARY Over 8+ years of experience in world class Auto-ancillary manufacturing companies in

various cross-functional areas like Continuous Improvement, Manufacturing Engineering, New Product Development, Industrial Engineering and Process Engineering & Improvement.

A strategic planner with expertise in managing NPD activities, streamlining processes / procedures to facilitate smooth production process & enhance productivity.

Well versed with Lean tools, Time Study, Work Measurement, FMEA, PPAP, APQP, TQM, Kaizen, 5S, Six Sigma, Layout optimization & Line balancing.

Proven ability in driving numerous Lean culture, quality enhancements, process improvement and cost savings initiatives during the career span.

Played a leadership role in developing and mentoring a robust process improvement mindset within the organization through Implementing lean manufacturing techniques.

Performed benchmarking studies to continually search for lean business system best practices and ensure standardization and compliance across the organization.

Estimating staffing requirements, production times and relative costs to provide data for operational decisions.

A keen planner and strategist with skills in troubleshooting, team building capability and abilities in planning and managing resources.

Improve the Processes by using Six Sigma Approach

Manager, Manufacturing Engineering & CI: October -2010 - Present

M/s. Eaton Industrial systems Private Limited, Ahmednagar & Nashik, Maharashtra

Eaton is a diversified power management company with more than 100 years of experience providing energy-efficient solutions that help our customers effectively manage electrical, hydraulic and mechanical power. A global technology leader, Eaton acquired Cooper Industries plc in 2012. The 2012 revenue of the combined companies was $21.8 billion on a pro forma basis. Eaton has approximately 102,000 employees and sells products to customers in more than 175 countries.

Eaton is a global technology leader in electrical components and systems for power quality, distribution and control; hydraulics components, systems and services for industrial and mobile equipment; aerospace fuel, hydraulics and pneumatic systems for commercial and military use; and truck and automotive drivetrain and powertrain systems for performance, fuel economy and safety.

The company is certified to ISO 9000 / TS 16949/ ISO 14001 standards. Eaton products are exported to across the globe.

The typical processes involved in manufacturing of Engine valves include, forging, Heat treatment, PTA welding, turning and grinding operations

During my stint with Eaton my key responsibilities included:

Implementing the Lean Culture in Plant.

Responsible for Improve Operation Excellence of the Plant through Lean Management.

Responsible for managing the complete New Product development activities & flawless

launches of New products.

Responsible for Implementation of Dedicated lines concept and Optimization of Plant Layout.

Responsible for Increase the productivity by reducing the cycle time and tooling losses.

Responsible for to study the received drawing and to confirm the manufacturing feasibility

and providing the inputs for costing.

Responsible for Man power requirement calculation and allocation to required

areas.

Responsible for Line Balancing with minimum Manpower and Optimum production.

Responsible for preparation and implementation of Capex Requirement Plan based on Strat.

Plan and Profit Plan.

Responsible for selection of Machine & supplier, Preparation of technical specification and

agreement with Machine supplier.

Responsible for Effective and efficient Capital spend by on time installation of New

Machinery as per Plan.

Responsible for Improving Manufacturing Profit by Cost Reduction. Productivity Improvement

& Yield Improvement Projects.

Responsible for finalization of Process Standards and Process norms.

Projects handled till date-M/s. Eaton Industrial systems Pvt Ltd, Ahmednagar & Nashik

Presently Leading Cummins India QSK 23 Valve development project

Lead the Honda NP1 Project & Ford DV5 Project under New Product development.

o Complete development of Engine valves from RFQ to productionization for Honda

Np1(Honda Brio) Engine Project in 2010-12

o Complete development of Engine valves from RFQ to productionization for Ford

DV5(Eco Sports) Engine Project in 2011-12

Lead the Nashik Best 2014 Project “Rapid”. Mainly focused on Improve the Line Capacity utilization & productivity improvement by optimizing the resources.

Project accomplishments:

o Man Power saved per Day from 42 to 33.

o Throughput time reduced from 121 Sec to 104 Sec(14% improvement).

o Capacity improved by 21% (from 4K to 4.8K per day)..

o Man- Machine Ratio improved by 35%

o Operator fatigue reduction by eliminating loading and unloading

Successfully Lead the Eaton Business Excellence certification Assessment in 2014.

Successfully implemented Multi-Machine Concept through layout changes and operator

Balance and saved 27 people per day(overall plant)

Successfully completed Productivity discussion & sign off with union during Wage

Agreement-2014-2017

Successfully implemented Part family Line concept in Nashik Plant

Lead the Nashik Best 2013 Project “EXECUTION”. Mainly focused on productivity improvement & CIF culture deployment, Apart from this focused on intangible benefits like operator fatigue reduction,

Project accomplishments:

o Man Power saved per Day from 24 to 18.

o Maintained with Zero Customer Complaint.

o Monthly avg. Production increased from 22K to 61K.

o Setup time reduced from 55minutes to 22minutes.

o Throughput time reduced from 143secs to 125 sec

o Operator fatigue reduction by eliminating loading and unloading.

Lead the Ahmednagar Best 2012 Project “PUMA”. Increase the Productivity by optimizing the Manpower and increase output through implementing Model Line Concept (single Piece flow without manual intervention).

Project accomplishments:

o Line Capacity per Day increased from 4300 to 6900nos.

o Per man productivity increased and Man Power saved per Day by 30%.

o Material Travel Distance reduced by 49%.

o Daily average output increased by 67% increase.

o Single piece flow implemented by reducing the WIP by 90%.

o Operator fatigue reduction by eliminating loading and unloading.

o Consumable cost saving by $26 K/Year through implementing new grade cutting fluid

and tools.

Successfully implemented Part family line concept in Ahmednagar Plant. In part

families, products are grouped by similar size, material, construction, in order to streamline

changeovers, increase throughput and minimize scrap.

Played champion’s role in Eaton Business Excellence certification for Process Design in

2011.

Lead the Best Gemba Kaizen event for the year of 2011.

o Gemba Kaizen event conducted for reducing the rejection due to high Seat run out.

By implementing the action identified in the Event, we reduced rejection 2.9% to

0.14%. This Project got appreciation award from ACMA team.

Successfully implemented People side change by using ADKAR model in Plant Layout

Modification.

Reduced operator fatigue in several operations by low cost automation and Auto loading &

Un loading arrangement.

Implemented dedicated Product layout concept (Layout Optimization) for all lines.

Played key role in improving plant capacity from 1.75 Mn/line to 2 Mn/line only by process

improvements without any addition of new equipment. Improved the Plant Capacity by

reducing the line Bottle neck Machines cycle time.

Lead Time Reduction by Continuous Improvement in layout changing and waste elimination.

Developed detailed agreement format for New Machine approval.

Asst. Manager, Manufacturing Engineering: Aug-2006- Oct-2010Present - M/s. RANE ENGINE VALVE LTD, Hyderabad

RANE Group is a leading manufacturer of automotive components in India with a consolidated group turnover of Indian Rs.15.6 billion.Rane Engine Valves was awarded the world’s most coveted honor for excellence in TQM - Deming Application Prize in the year 2005. The company is certified to ISO 9000 / TS 16949/ ISO 14001 standards. Rane products are exported to over 19 countries across the globe.

During my stint with Rane Engine Valves my key responsibilities included:

Responsible for managing the complete New Product development activities.

Preparation, updating & control of product & process related documents (Control plan, SOP).

To study the received drawing and to confirm the manufacturing feasibility.

Calculation of consumable cost, power cost, raw material cost & man power cost at the time

of Quotations for New products.

To conduct CFT meetings for preparation of APQP Timing Chart & review of FMEA.

To prepare update & submit PPAP Documents.

Capacity enhancement & man power calculation based on Annual Operating Plan(AOP).

Commissioning of New machines. Part Productivity standard developments through Time

study.

Process improvement through Process validation.

Projects handled in M/s. RANE ENGINE VALVE LTD, Hyderabad:

Lead the Tata Nano and Tata 3ltr Valve Project under New Product development.

o Complete development of Engine valves from RFQ to productionization for

TATA Nano Engine and TATA 3ltr Engine Project in 2008-09

Reduce the Plant level consumable consumption cost by 18% through standardization.

Preparation of Work standards for all operations through time study and convinced the

management & operators at the time of Long term agreement (2009-12).

Lead the Cummins VE project for Price Reduction by 40%. Project won the Award

for best VE from Cummins in 2010.

Developed & created the line for M & M Eagle with capacity of 5000 valves per day.

Lead the DEUTZ Capacity enhancement Project and increased the Capacity from 3000 to

8000 valves by installing new machinery.

Lead the best Lean Project in 2009 for Line 1 Capacity Improvement.

Project accomplishments:

o Line Capacity per Day increased by 14% increase.

o Per man productivity increased and Man Power saved per Day by 40%.

o Material Travel Distance reduced by 35%.

o Single piece flow implemented by reducing the WIP by 83%.

o Floor Space saved by 38%.

Reduce Raw material consumption in Engine valves by optimizing the machining

allowances.

Development & Manufacturing of engine valve for various engines.

PROFESSIONAL TRAINING PROGRAMS ATTENDED

“Break through Improvement by Six Sigma” training organized by Confederation of Indian

Industry (CII).Duration 2 days

Lean Six Sigma Training organized by IACT Global. Duration 6 days

Six Sigma Green Belt Training organized by IACT Global. Duration 6 days

Training on Continuous improvement Frame work. Duration three days.

Training on Change Management with ADKAR Model. Duration is three days.

Internal Combustion Engine emphasis on engine valves organized by IIT MADRAS.

Duration 78 hours.

Training on APQP, PPAP, FMEA, KAIZEN, DOE, 7 QC TOOLS,SPC.

Training attended on Lean production system by Dr. Takahashi San.

Engineering Manpower Development Program” conducted by RIED. Duration One month.

TQM Awareness Programs. Daily Routine Management (DRM) by Dr. Washio from JUSE.

Training on Work study & work measurement. Duration three days.

PERSONAL DETAILS

Date of Birth : 4th April 1982

Languages known : English, Telugu

Marital Status : Married.

References : Gopala Rao, Ex Rane Plant Manager.

Subhodh Govardhan, Ex Eaton Plant Manager.

Communication address : Phani Kumar,

Flat No: 1, Samrudh Recidency,

Behind Day Care School, Ramnagar,

Nasik-422 009, Maharashtra

DECLARATION

I Phani Kumar herby declare that the details mentioned above are true to the best of my knowledge and abilities.Date:Place: (Phani Kumar)