Sonawane Prabhakar

Experience

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  Shareen Auto Pvt. Ltd

  Dec 2003 - Nov 2004

  Trainee production Engineer (CNC M/C Section)

  Production Engineer in CNC Machining section.

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  Mungi Engineers Pvt. Ltd.

  Dec 2004 - Jul 2007

  Production Executive (BIW Cargo Assembly)

  Production executive in sheet metal Cargo assembly shop.

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  Mahindra CIE Automotive Ltd.

  Jul 2007 - Oct 2009

  Production Engineer (BIW Sub assembly )

  Assembly production Engineer

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  Reliable Autotech Private Limited

  Oct 2009 - Feb 2011

  Executive Project leader - Engineering & Development (BIW/Sheet Metal)

  Project leader in Engineering and Development.* Worked in Program management department as a Project leader. Coordinating Project Development activities of John Deere assemblies according to the APQP system.* Experience in Press shop & Press parts assembly weld shop Production, Process, Engineering & Development, NPD & Projects in BIW/Weld shop.* Project leader with 2 subordinates responsible for ECN, RFQ & JD Brake pedal assembly project. * The major task converting the RFQ in real business. Process Planning, development, validation & Improvement on Projects.* Timely implementation of ECN & Handover the project to Production team. Line Layout finalization. Line balancing & single-piece flow.* Exposure in Stamping processes, Machining & Robotic Welding processes. Handling of Change Management (ECN) of all the customers. PCN at assembly welding line.* Handling of RFQ of press parts & welded assembly of various Customers like JD, Trelleborg Automotive, Bentler, VW, Skoda, etc.* Capacity planning of equipment’s, material handling equipment’s, trollies, pallets, bins, Line layout finalization, Time & motion study to achieve the desired output as per customer demand.* Preparing the Project Planning in APQP Timeline, Initial team feasibility. Communication with customer for DPAR for approvals, Feedback on Project Status. Feedback of Customer, Risk assessment & action planning on project related activities.* Generation of SAP-related data, BOM Preparation. BOM Routine, Material master creation.* Trial, prove out & buyoff of press Tools, Jigs, welding fixtures and checking Gauges. Cost saving projects in VAVE Show less

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  Mahindra Group

  May 2011 - Jul 2023

  * Worked in XUV BIW shop for 5 years as a Production In charge. Worked for 7 years in Scorpio Body shop. Weld shop Production, Process, Engineering & new Projects.* Shop floor management, operational & Quality control with TPM approach. Standardization of operation, On Time completion, quality, safety, and ease of operation.* Outstanding man management & interpersonal skill to maintain harmony amongst them. Training as per dexterity school (Gurukul). OJT & versality as per 3x3 matrix. Multiskilling & Deskilling of operation.* Identifying bottlenecks in BIW assembly process & improvement. Continuous improvement in the Quality & services. Quality systems like ISO, DCP, APQP, PPAP, and MAPS.* Spot welding process parameters validation. Fixture checking & validation (M1, M2, M3) trials & Fixture Buyoff.* Strong in implementation of TPM JH Pillar. OEE & OLE monitoring & improvement.* Managing Quality Systems for meeting the standard requirements of Mahindra guidelines using tools like PPM, PFD, Control Plan, FMEA, PPAP, Kaizen and POKAYOKE* Practiced with the use of scientific work measurement technique like MOST. Involved in LTS 3 times. Achieved 32% productivity rise. Cycle time reduction, line balancing & single piece flow.* Experience of jig & fixture correction & trouble shooting as per the CMM report for 3D PIST/1D PIST improvement. CTQ improvement for TCF assembly fitment. Enhanced body closure PIST from 62 to 84%.* Reduction of Robotic cycle time, process time by Robot teaching. Trial, prove out & buyoff of Jigs, welding fixtures and checking Gauges.* Maintaining all relevant documents of ISO 14001-2015, ISO 45001- 2018, MAPS & TPM.* ‘Mahindra Yellow Belt” Certified 5 times quality concern resolution. HEP, low-cost automation. * Safety synergy, accident investigation, BBS, CCTV, safety abnormity, SOT, Patrol round. Unsafe act & unsafe conditions.* Weld integrity, Sealer integrity quality parameters management for ensuring world class vehicle quality. Show less

  • Deputy Manager - BIW Production (XUV 300 & Marazzo Body- Passenger Vehicles)

    Aug 2016 - Jul 2023

  • Assistant Manager - BIW Production (Scorpio & SC/DC Body - Passenger Vehicles)

    May 2011 - Aug 2016
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  Force Motors Ltd

  Aug 2023 - now

  Manager - BIW Manufacturing Operations (Urbania & Bus Body Building - Commercial Vehicles)

  * Handling all the entire manufacturing operational activities in body shop. Manage a team consisting of 200 technicians and 7 officers including GETs. * Responsible for achieving Production department KPI’s in line with the organization objectives. Major responsibilities of ensuring quality products and productivity of the department. * Responsible for Line Production, delivery, revenue cost, Safety, Quality & improvement activities.. Conduct FAMC, MRM & prepare action plan.* Daily work management (DWM). Tracking & monitoring of all the DWM points related to production, process, maintenance, quality, press shop & RI with closure of action plans. * Reviews meetings of KRI on daily & weekly basis at all the areas. Skill matrix of technician, 5S on shop floor, Kaizen, Technicians involvement, suggestions.* Monitoring all the parameters of PQCDSM through daily work management. Coordination with PPC & service dept.* Daily breakdown & minor stoppage monitoring. PM adherence & MTTR Kaizens.* Model Line TPM implementation and Improve MTTR and MTBF.* Ensure daily OEE targets are met by focusing on Performance losses (Cycle time), Availability (Down time reduction) and Quality (Rework & Rejection reduction). * Ramp up & speed up the production volumes by pulling the resources & Set the production targets as per IED timings & norms, Time study & SMM.* Customer concerns handling on line along with Quality Assurance team:Round table meeting, Containment, 8D resolution, 5 Why/ Root cause analysisICA & PCA implementation. * Rework & rejection analysis through PNCN, CAPA. Monitoring the COPQ & prepare the action plan.* Promote & practice “safety first” policy by addressing all hazards, defective equipment & unsafe conditions immediately.* Accident investigation, reporting & follow through of corrective action items for near miss & safety incidents* IATF 16949 certified Internal auditor. Quality chronic concern resolution through QCC. IATF & EOHS Audit preparations. Show less