Karthik Tirukkovali, CSSGB

Experience

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  Mahindra & Mahindra

  Aug 2012 - Feb 2016

  Key result areas:1. Develop optimum production setup according to monthly demand changes by line balancing, and manpower Calculation as per Maynard operations sequence technique (M.O.ST).2. Conduct Method study, Motion study, Work sampling and prepare process documents such as ECN, PCRN, SOS (sequence of steps)/S.O.P, Work elements & work guidelines according to TAKT.3. Conduct capacity analysis and prepare action plans for debottlenecking high work content stations.4. Prepare and maintain work content data in SAP and aid in vehicle costing through routings creation.5. Analyse and improve value chain and transport models using tools of Value stream mapping analysis and Maki-gami analysis.6. Planning optimum use of available resources such as manpower and equipment during implementation of process changes, engineering changes and new vehicle development. Monitor efficiency of production through day to day calculation of E.W.T, O.L.E, O.E.E & O.P.E parameters.7. Prepare action plans for improvement of productivity by Loss analysis, ECRS methods and benchmarking of best practices with other OEM’s.8. Accomplish business goals through Kaizens, Process changes, Engineering changes and control plans.9. Prepare drawings for assembly line layouts, tools, fixtures etc with Auto CAD, CATIA, Uni-graphics and plan for implementation for process changes and improvements.MAJOR PROJECTS:1. Installed sealant recovery system in Paint shop saving cost of Rs.6 lakh per annum.2. Increased productivity in paint shop by 36% through single link implementation and trolley length reduction.3. Increased productivity in assembly lines by 30% through Implementation 60, 70 & 91 setups.4. Saved 15 lakh /annum by reducing 10 man power through stage layout change, Kaizens and automation.5. Eliminated two high fatigue stations by in house fabrication of lifting mechanism and stage Relay out. Show less Work study and time study using MOST (Maynard Operation Sequence Technique).Line balancing & Guide lines preparation/Man power planning and implementation.New setups implementations: Preparing guidelines for implementation of various setups.Capacity enhancement.o By doing bottle neck elimination.o Cycle time reduction.o Layout changes.Productivity improvements: o Work content reduction by improvements.o Cycle time reductions: Reducing cycle times by ECRS methods.Process planning & implementation for Assembly lines.MAPS (Mahindra Advanced Production Systems) implementation/WSS: Standard operation sheet preparation (SOS)/Ergonomics analysis (SSES and V3 analysis)/TPM implementation/Design changes implementation.Conversant with DCP, APQP, MPPAP, 7 QC tools, Poka-Yoke.Identifying scope for modifications in inspection, process flow, working practices, consumables etc. for controlling & reducing conversion cost per unit produced & preparing process sheet and DCP.Executing cost saving techniques/ measures and modifications to achieve substantial reduction in expenditures and work within the budget with use of Value engineering.Focusing on optimization of process parameters; initiating process improvements and up gradation for achieving bottom line objectives and productivity targets.TPM Expert. Show less

  • Deputy Manager-Industrial Engineering | Time study | Lean Manufacturing

    Aug 2015 - Feb 2016

  • Assistant Manager

    Aug 2013 - Aug 2015

  • GRADUATE ENGINEER TRAINEE

    Aug 2012 - Aug 2013
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  TATA Advanced Systems Limited

  Feb 2016 - Oct 2018

  Deputy Manager-Industrial Engineering | Project planning | Kaizen facilitator

  Responsibilities undertaken:1. Optimum Direct and Indirect Manpower planning in New programs prior to production start based on “Craw Ford learning curve method”.2. Capturing of Man hours burnt on production shop orders, performing VA-NVA analysis, identifying scope for improvements and taking necessary steps to reduce NVA.3. Line balancing of Hours and Preparation of Crew load chart (Day to Day schedule) with optimum planning of manpower and TAKT.4. Capacity planning and identification of scope for additional shipsets.5. Preparation of Integrated Master Schedule and monitor the status of project on a weekly basis.6. Preparation of Recovery plan in case of Schedule slippage.7. Perform MOST study on production operations and calculation of Standard time for resource optimization8. Improve 5S on the shop floor through monthly auditing and identification of improvements.9. Kaizens implementation to improve Safety, Quality, Cost and Throughput.10. Perform Ergonomic analysis,(REBA,RULA,MFA) and implement Kaizens to reduce the fatigue on the operator.MAJOR PROJECTS:1. Eliminated Bottleneck through NVA optimization and achieved Customer demand of 2 SS/Month.Reduced 3 manpower through MOST study, NVA reduction and optimum Line balancing.2. Played a Crucial role in planning and development of “Project Apache-Secondary structures project” and achieved “1 month early production start” through efficient planning, monitoring and controlling.3. Increased Business by effectively planning 17 additional Spare deliverable requirements in addition to initial orders. Show less

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  Thermopads Pvt Ltd - ThermoGroup

  Oct 2018 - now

  Industrial Engineering Manager | Lean six sigma | Continuous Improvement | Manufacturing Engineering

  Working in the capacity of Group Industrial Engineering & Process engineering Head with operational activities across 3 Subsidaries-Thermopads,Thermo cables and Thermosystems.Key responsibilities Undertaken:1.Studying & Identifying capacity constraint areas across processes stages and deriving improvement ideas to increase Organization overall capacity.2.Designing of Solutions,Automation,Equipment and fixtures to reduce process cycle time,Machine idle time, and changeover time.3.Implementation of Industry 4.0 solutions viz. IOT technology,Robotic process optimization (RPA),SAP customized ABAP modules , Artificial Intelligence(AI) software , Manufacturing Execution systems(MES) software, for automatic machine OEE data collection,Order tracking,fool proof packing and process cycle time reduction.4.Deployment of Value stream mapping across Man-Oriented processes and deriving improvements to reduce Manpower & Cycle time.5.Finding competent suppliers for deploying Automation solutions&Equipment and finalizing Purchase contracts with scope document preparation.6.Procurement&Installation of Material Lifting and Handling mechanisms to save floor space and reduce setup time of machines.7. Intitiating Buisiness Impact projects to reduce customer complaints in Production and Packing processes. 8.Standard time calculation through Time study & Motion studies and implementation of layout changed to reduce Non value added activities and Increase output. Show less