Surendra Kumar Sahu

Experience

• 

  Force Motors Ltd

  Jul 2003 - Mar 2008

  Senior Production Engineer

  Role:• Planned output levels & supplies to customer shop/super market on day to day basis• Ensured that:o All operators achieve production norms and took efforts to establish new norms & improve productivityo Tools/consumables are available & consumption as per norms• Drove the efforts for ensuring that required gauges, fixtures, material handling equipment, etc. are available in the cell and are properly maintained / calibrated• Coordinated with Module Manager for implementation of best practice such as TPM, TQM, Pear String Production, etc.• Served as a coordinator for all shift in cell and maintained cordial relationships & discipline within cell• Oversaw super market stock (optimize inventory status)• Guided & supported team leaders to achieve SQDCME objectives through standardized work• Assisted work groups as required for maintaining production flow consistent with cycle time• Monitored Andon occurrences and provided secondary support as first responder Highlights:With Force Motors Ltd.• Daimler Benz (Germany) Press Tool Tryout and modification for export & production of press parts• Project handle L200 MAN (ASTRIA) Press Tool Tryout and modification as per presses availability • Received appreciation from our CMD Mr. Abhay Firodia for timely completion project L200 MAN• Handled project of NEW TRAX tool tryout of press parts• Took cost saving initiative and saved 6.2 lacs/annum from Jul’03-Sep’05• Holds the credit of maintaining rejection control up to 70%• Played a key role in improving quality improvement in skin panel of T-1 & FMTV export• Played a pivotal role in developing die library and establishing super markets which resulted thurst increment in SPM 4 TO 6 .2 SPM in 2004-05 Show less

• 

  Tata Motors

  Mar 2008 - Oct 2021

  • Prepared justification for all Capex items & budget release from corporates and Capex for capital enhancement & sustenance projects• Identified & analyzed credibility of suppliers through market/ industry feedback and secondary sources• Organized technical study on consensus with user & other agencies and prepared RFQ• Sourced reliable vendors based on experience, floated RFQ to them and received techno-commercial quotations from more than 3 suppliers• Accountable for finalizing capital equipment by technical & commercial evaluation by using various negotiation tools like e-bidding, tendering, etc.• Interfaced with suppliers for negotiating on techno-commercial terms which includes price, payment, delivery, DAP, installation commissioning plans, taxes, etc.Highlights:Title: BIW Turnkey SetupCost: 46 Crores Description: Strategy planning with business case for new BIW line set up at TML Lko. Role:• Handled a gamut of activities like making various schemes, planning for complete facility & capacity, analyzing area, manufacturing feasibility, preparing RFQ, obtaining budget approval from COP Show less • Ensuring improvement in operational safety at CX Level and closure of all CX level issues to remove unsafe condition• Involved in identifying unsafe acts / conditions through safety observation process, setting up incident investigation plan for identifying root causes & mitigating identified risks, train employees and create awareness• Guiding, motivating and improving employees to encourage safe behavior & ensure compliance of PPEs & SOP• Stellar role in meeting production targets through identifying & addressing delivery issues by implementing Pokayoke, method & process improvements, Complexity Reduction. Show less Project Title: Weld Shop Turn key setupProject Description: Strategy planning with business case for new BIW line set up at TML Lko Various schemes making, complete facility planning, capacity planning, area analysis, manufacturing feasibility, RFQ preparation, Budget approval from COP. Project is in progressive stage Highlights:With Tata Motors Ltd.Title: Centralized Fumes Extraction System in BIW Cost: 2.2 CroresDescription: Centralized fumes extraction system consist of ducting in entire BIW shop, installed fan & filter units, CMH estimation, automatic dampers, VFD, extraction arms, sensors, etc. for extraction of welding fumes generated from MIG welding. Title: Main Frame Fixture in BIW Cost: 1.5 croreDescription: Main frame fixture was ordered for BIW cab assy. It was used for geometry making by welding (Front wall, roof, substructure & rear wall). The scope included scheme finalization, detailed planning, RFQ, user concurrence, budgeting, vendor selection, ESR making, P.O., DAP, PDI, installation & commissioning. Highlight: Project ran successfully with desired o/p.Title: Roof Inversion SystemCost: 0.7 croreDescription: Roof Inversion System was a complete transport unit which transported roof from station start to last station. Scheme finalization, RFQ, etc. Total 5 vendors were selected for commercial & technical bid. Detailed technical comparison was prepared with Executive Summary ReportHighlight: System is working satisfactory in BIWTitle: Substructure Fixture in BIWCost: 1.6 croreDescription: Substructure was planned for assy of substructure assy for CAB in BIW, detailed costing of project, discussion with vendors on scheme, layouting, cycle time, no. of fixtures, welding accessibility, quality parameters, etc.Title: Spot Welding & MIG Welding Guns in BIW Cost: 0.8 croreTitle: Door Handling System for Fitment of Door in CABCost: 0.3 crore Show less

  • Senior Manufacturing Manager

    Mar 2016 - Oct 2021

  • Senior Manager ,Weld Shop manufacturing

    May 2010 - Mar 2016

  • Project Manager

    Mar 2008 - May 2010