Neeraj S.

Experience

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  Diesel Locomotive Works Varanasi

  Jun 2017 - Jul 2017

  Internship Trainee

  •DLW (Diesel Locomotive Works) is a production unit of diesel engine in Varanasi Uttar Pradesh under the ministry of Railway.•I did my internship here for two month where basically i went through four major shops.1-Engine testing shop (ETS)‣After completing the assembly of engine ,here we tested the engine by filling the lube oil and fuel ,testing of vibration ,controlling of temperature & pressure and circulating of water.2-Truck machine shop (TMS)‣In this shop we have seen whole assemble of wheels in the truck ,wheel and axel assembly ,traction motor and gear case assembly ,brake rigging assembly ,bearing adopter assembly and final assembly.3-Heavy machine shop (HMS)‣In this shop various operations happened as lathe machine used for producing cylindrical works ,shaper machine used for producing flat surface in vertical & horizontal planes ,drilling machine for drill bits for cylindrical holes ,milling & grinding operation for smooth surface.4-Maintenance area -2 (MA-2)‣This shop for basically daily care to check safety guards ,check oil level for lubrication and hydraulic system ,cleaning of machines & tools and prevent damages. Show less

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  Technofast CAD & IT Training Centre

  Aug 2017 - Oct 2017

  Internship Trainee

  •Auto CAD (Basic and advance)•Solid work 3D

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  OPPO

  Jun 2018 - Jan 2021

  Cost control: We have to take care about all manufacturing cost (except BOM material) , weightage contain as labor cost (DL) 41% & IDL 10% ,Low consumable 15% ,Depreciation 10% ,Food & transport 10% and power 5% . •We are calculate labor cost per device in terms of money (CNY).Also done a project on cost reducing from 1.15 CNY to 0.85 CNY per device via DMAIC approach ,which is completed in 4 months .•In low value consumable major was three types of consumption ,first was production consumable (gloves ,tweezers ,anti static aprons etc.) ,second was machine parts and third was jigs & fixture ,every week we analyzed the data and found unreasonable consumption or wastage ,try to control via making rule ,caring ergonomics and documents.•In depreciation charge major was CMW & industrial computer ,which were taken on rent for use ,this planning did by IE .Project approach or DMAIC:•IE dept. initiate some projects towards improve efficiency and reducing cost for itself and other department also , some project which is done from my side are following...1-Reduction of 1.5 manpower from one line of SMT per shift2-Cost reducing from 1.15 CNY to 0.85 CNY per device3-Two manpower reduction from TRC (repair team) per shift4- Execution of auto scanning in PCB cutting machine to save time (6 sec per 15 PCB) •Analysis of losses between IE standard vs PPC planning vs actual production (yield) ,make report to show management and extract the actual reasons of losses & further create project for improvement. Show less Resource planning: (New product introduction)‣Jigs & fixture ,stencil and machine planning:•First of all we receive the plan quantity from sales & PPC for a particular model or Project •According to that plan we calculated no. of required lines with the help of china NPI team as they told us the basic ergonomics about model like cycle time or UPH or videos•After that we decided the no. of machines and supported equipment•Start the cal. of no. of jigs & fixture based on no. of lines and decided the vendor to developed jigs & fixture in optimum cost ,design preparation of jigs & fixture did in solid edge ,AutoCAD and Gerber file in GerbMagic software•SOP ,Machines and all jigs & fixture we had to finalized and carried to equipment room before 15 days of model start on shop floor‣Manpower planning:•Every week and every month we had to review the manpower quantity with respect to IE planning and absenteeism & abscond rate •We checked according to future plan ,how many manpower we required ,if needed more then start the process of hiring through HR department•If the existing manpower more than requirement ,then we will deploy the extra manpower in other work or planned holiday to save our transport & accommodations charges•Code routing: New model part code need to route in ERP which insure that factory is ready to make this product with all the required resources ,After code routing PPC can release the work order for production.Efficiency improvement:‣OPE and OEE:•Calculating the overall plant efficiency through the i/t hours and o/t hours ,i/t hours is the available standard production hours of the manpower & o/t hours is the utilized standard hours according to the final yield•Calculation of overall equipment effectiveness •Major purpose to calculating these data was , analyzing the data and finding the exact reason behind the major losses (80/20 Rule) , show to respective department and push towards improvements with some incentives to motivate them Show less •Preparation and releasing the work instruction & standard operating procedure (SOP) ,where define detail manufacturing process in terms of production & quality check points.•Change in SOP according to the EPC (Engineering process change) and ECN (Engineering change notice) via MO (My office) approval with the all related dept.•Create the process flow diagram (PFD) for a new model (product) or project and end to end process design.•Preparation of the line layout & production floor layout in AutoCAD with the help of china CAD file and set up the line according to the layout with the help production & maintenance department.•Prepare Ramp up plan during new Product Introduction phase with an effective training session to meet customer forecast.•Preparation of cycle time assessment report to achieve the customer forecast demand.•Line balancing (LOB) on the basis of cycle time report via found the bottleneck station •Improving the process by ECRS (Eliminate-Combine-Rearrange-Simplify) techniques .•Analyze operator ergonomics & Fatigue to each assembly ,Test stage & packing stage and plan to eliminate NVA activity.•Design test station setup to consider operator ergonomics and improve or changeover execution at minimum standard time by SMED (Single-Minute Exchange of Die) tool.•Calculation of UPH and UPPH of every station and lines in SMT section in terms of improvements and to meet the assembly (customer) demand.•Reduce the machine cycle time in SMT lines with the help of machine maintenance team for setup the capacity.•Regular small Kaizen improvements project on the monthly basis.. Failure analysis and their Root cause analysis. Show less

  • Engineer-IE

    Jan 2020 - Jan 2021

  • Engineer-IE

    Jan 2019 - Dec 2019

  • Graduate Engineering Trainee-IE

    Jun 2018 - Dec 2018
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  Tata Electronics Pvt. Ltd.

  Jan 2021 - now

  Talks about #tatagroup, #industrialengineering, #PMTS, #leanmanuafacturing, #workstudy, #businessexcellence, #layout, #simulation, #dataanalyis (New Greenfield Project in Electronics Manufacturing industry)1-Plant & line layout preparation and machines placement.2-MHE (material handling equipment) project handling for new plant in manufacturing & assembly section.3-MOST coding for all processes to make a base line.4-Manpower and other resources planning.5-Cycle time reduction ,multi manning and part flow analysis on new introduced assembly line .6-Plant simulation.7-Lean practice.

  • Assistant Manager-IE

    Apr 2023 - now

  • Senior Engineer-IE

    Sept 2021 - Mar 2023

  • Executive-IE

    Jan 2021 - Aug 2021