Onkar Kulkarni

Experience

• 

  John Deere India Pvt. Ltd. (JDTCI)

  Oct 2001 - Feb 2008

  Manager Manufacturing Engineering- Machining

  Joined as Production Engineer Trainee in joint venture L & T John Deere Ltd. which later in Sep 2005 taken over by John Deere. With increasing responsibilities led the team of Manufacturing Engineers to establish the state of art machining facility to support cast iron structural housing inhouse machining for Transmissions & Engines with annual capacity of 50K.• Achievements :• Hired and motivated the team of 80 CNC technicians and 8 staff members.• Successfully led and managed 8 new tractor projects with complete CAPEX responsibility.• Continuously strived for new technology introduction to achieve the minimum 15% perishable tool cost reduction year on year with process, cycle time and quality improvements to meet the increasing demand.• Introduced the Productivity Improvement Programs with the help of key Global Tooling suppliers and achieved the 10% improvement in productivity.• Established the productivity standards through personal demonstrations, scientific time studies and ergo improvements to improve the productivity by minimum 10% every year.• Key member to implement SAP, MES, etc.• Led the machining department for QS9000, ISO9001, ISO14000 and Deere Production System (DPS) certification.• Served as machining expert to support supplier development team for evaluating and optimizing supplier process and tooling requirements. Show less

• 

  John Deere

  Feb 2008 - May 2015

  • Managed commodity purchase teams for Hydraulic, Power Module, Electrical/Electronic commodity and Import parts for 4 manufacturing units in China.• Led multiple new product & SKD/CKD projects for 6 different product lines.• Enterprise process lead for supply management lane to define and execute new product introduction and SKD/CKD product launch processes.• Led continuous cost reduction/value improvement activities to support SVA growth.• Managed project metrics and performed administrative duties to support the HR processes.• Achievements :• Managed spend of $600 Mn.• Enterprise process lead for supply management lane to define and execute new product introduction and SKD/CKD product launch processes and supply management deliverables.• Achieved $10K savings per machine for SKD/CKD projects through localization.• Consistently exceeded the metrics and performance results. Show less • Led and mentored the unit supply management teams for Supply Chain Integration (SCI) and Enterprise Product Delivery Process (EPDP) to ensure processes are implemented uniformly across all units to meet cost, schedule, quality and delivery goals for new product programs.• Implemented, continually monitored, and developed the Supply Chain Integration sub-process in EPDP to continually enhance supplier integration at units and seamless transition of new product programs to production through regular interaction with operations teams.• Supervised individual contributors and provided work direction to several individual contributors in support of Product Delivery Process (PDP) programs.• Achievements :• Successfully executed 12 major projects for 3 product lines over 4 business units.• Achieved $2K savings per machine through localization.• Raised John Deere’s internal Quality Production System (QPS) assessment PDP lane score from 33% to 93 %.• Collaborated with unit cross functional leaders to gain alignment and support for key initiatives to ensure end to end supply chain for the project.• Developed, tracked, and reported Unit SCI metrics to Division leadership and key stakeholders to ensure alignment with goals. Show less • Manager Tactical Procurement & Indirect Materials :• Managed factory team to ensure processes and strategies are implemented to meet cost, schedule, quality and delivery goals to support operations and activities for both direct and indirect materials.• Ensured an uninterrupted supply of materials and services, conformance to Achieving Excellence and cost-reduction goals to support operations and introduction of new products.• Monitored and executed inventory project plans to achieve inventory management and material flow goals.• Achievements :• Days on Hand (DOH) inventory reduced by 50% through lean concepts.• Delivery PPM improved by 30%.• Introduced supplier managed inventory (SMI) project to bring 2% operations cost reduction annually.• Established and strengthen the procurement processes and recovered $200K through warranty recovery.• Successfully designed and established Cost Per Part payment agreement with Mapal Toolings for inhouse machine shop. Project brought the yearly 25% savings on perishable cost, 0 material variance and 15% improvement in QPPM.• Manager Manufacturing Engineering :• Responsible to drive machining projects in both JD owned factory and Government JV factory.• Managed and led team of manufacturing engineers.• Developed and managed capital budget and executed the projects by following Deere Production System (DPS) to meet cost, quality, safety, delivery, environmental, etc. needs and successfully delivered the facility to operations for serial production.• Achievements :• Installed 23 CNC machines to support annual demand of 30K production units for structural housings.• Introduced lean manufacturing practices for fixtures, tooling and processes with 30% cost reduction on capital investment & 40% cycle time reduction for existing products with engineering and technological improvements.• Improved asset utilization by 20%.• Successfully led and managed 3 new tractor project’s inhouse machining. Show less

  • Manager Supply Chain Integration - Growth Projects - Regional, China

    Aug 2012 - May 2015

  • Product Line Lead - Tractors (Utility, Mid & Large) - China

    May 2010 - Jul 2012

  • Manager Manufacturing Engineering & Tactical Procurement & Indirect Materials - Tianjin Works, China

    Feb 2008 - Apr 2010
• 

  John Deere India Pvt. Ltd. (JDTCI)

  Jun 2015 - now

  • Leading staff of supplier development engineers and establishing production standards for the supply base in the region across all commodities in compliance with the regulatory requirements of region.• 300+ direct material suppliers• Providing production assistance to suppliers to minimize negative operational impact. Solutions to improve performance of underperforming suppliers and planning assistance to meet the company's build-to-demand flexibility and seasonality initiatives.• Leading special project teams in defining and implementing processes or solutions. Identifying and executing crucial process improvement projects and ensures alignment with unit and/or division strategic initiatives.• Managing supplier risk issues such as performance, financial, compliance and event risk and developing appropriate mitigation plans.• Leading global sourcing of aftermarket parts procurement and development process in region to support parts business growth.• Performing administrative duties related to performance management, salary pay plan, succession planning, resource planning, training, and development of direct reports. Show less • Led team of strategic and operational buyers with responsibility of sourcing of factory services, materials/consumables such as MRO/PPE to support the operations, new project developments, facility expansion across India manufacturing facilities.• Analyze spend and evaluate suppliers. Consolidate spend across supply base to create leverage, analyze purchasing trends and develop sourcing alternatives. Identify new high potential suppliers.• Responsible for end to end purchasing process - ensuring all commercial terms are agreed and documented. Negotiate and execute NDA, SOW's and Master Purchase Agreement appropriately including legal review before business is initiated.• Evaluate and provide guidance to team on final selection of suppliers; Perform value analysis for final selection of suppliers. Drive continual cost reduction and avoidance initiatives.• Manage supplier relationships and performance, including but not limited to dispute resolution.• Evaluate supplier core competencies and competitiveness.• Achievements :• Centralized the indirect materials and services procurement system along with documented standard operating processes with clear roles and responsibilities for better compliance and ownership.• Established the John Deere branding and merchandise production and sell process first time in India region.• Managed the yearly spend of USD 41+ Mn with consistently strong rating in yearly audits.• Successfully managed new projects with 20% capital cost reduction.• Established warehouse management process with periodic cycle counting, inventory optimization, obsolete parts disposal & waste management.• Cost effective and smooth changeover of 3PL service provider without operations interruptions.• Managed various key contracts including scrap disposal, employee canteen and transport services, inbound and outbound logistics services, facility maintenance, lease facilities, etc.• Introduced automation in procurement process. Show less

  • Manager Supplier Development, Risk Management & Warranty - India & SE Asia

    Mar 2019 - now

  • Manager - Indirect Materials & Services - India Manufacturing Sites

    Jun 2015 - Feb 2019