Amarsingh Phalke

Experience

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  Tata Motors

  Oct 2013 - May 2015

  Assistant Manager (Design and Operations)

  - Facilitated design and development of gas balancer, window regulator and door check strap mechanism from conception to validation by interacting with suppliers, indoor and outdoor testing team, manufacturing engineering team and quality management team.• Operations Planning and Supply Chain Management: Performed sales and operations planning using mixed strategy (constant workforce and zero inventory), which led to cost saving of $9000. Managed sales data to analyze seasonality and trend in global sales and created weekly reports to assist supply planning and material management.• Production Planning: Developed master production schedule using MRP, optimized inventory to achieve 97% fill rate. Efficiently planned production for a product mix of 8 items using EOQ lot sizing model with capacity constraints. Improved the plant throughput by 11% and performed continuous improvement using PDCA.• Root cause Analysis and Six Sigma Projects (DMAIC): Part of cross functional teams to identify root cause of failures. Proposed appropriate solutions to the problems and successfully implemented necessary solutions by working on tools like Ishikawa diagram, GD&T, PPAP, SPC, APQP, DOE, X-bar and R charts, gage R and R analysis, six sigma.• Assembly Line balancing: Calculated number of workstations required to balance the assembly line. Developed plant layout to provided efficient man-material movement and floor utilization. Implemented 5S and designed workstation layout to reduce process time. Performed inventory cycle count using ABC analysis.• Production Scheduling: Performed production scheduling to optimize ‘mean flow time’ and reduce the number of tardy jobs by 17%. Created a ‘Heijunka model’ which assisted in production leveling.- Devised excel and CATIA Simulation based tool for window regulator kinematics and also excel based tool for automotive door energy calculation. Show less

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  Bloom Energy

  May 2016 - Aug 2016

  Quality Engineering Intern

  • Created an automated quality dashboard by writing excel macros to analyze defect database by extracting data from oracle and generated quality metrics control charts to improve the KPI’s like First Pass Yield, Defect per Unit and rework time of the product by establishing quality control tools and finding root cause of failures. • Performed Time and Motion studies on production line to improve cycle time by eliminating non value added work.• Implemented Lean manufacturing principles to reduce WIP and prepared future value stream map to reduce waste.• Standardized work element sheet by sorting work elements in such a way that production line is balanced and meets Takt time which reduced per unit cost of the product. Show less

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  Southwest Airlines

  Sept 2016 - Dec 2016

  Supply Chain analyst intern

  • Analyzed the inventory across six locations and performed cross-balancing to optimize the inventory cost.• Built a multi-echelon inventory model which reduced average lead time for parts by 32% and created a data visualization dashboard to monitor KPI’s which assisted in fast business decision making.• Worked on reducing inventory by over 15% by optimizing and re-establishing MOQ and Reorder point.• Performed forecasting, supply planning and material planning which led to reduction of Stock-out cost.• Built network models and performed route optimization using supply chain modeling to save $10000 annually.• Streamlined process map to reduce the lead time for fabricating in-house airplane repair parts. Show less

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  Schlumberger

  Jul 2017 - Apr 2019

  Production Planning Industrial Engineer

  • Performed Material Requirement Planning and manufacturing resource planning using Oracle and statistical analysis tools to meet KPI ‘On-Time-Delivery’ of 95%.• Performed Master Production Scheduling and maintained all MRP planning and scheduling parameters for all make items.• Analyzed Planned Order reports and provided timely release of Production Work Orders specified by production plan. Also interfaced with Procurement and production teams to prioritize the most critical items.• Identified and brought to resolution any production supply/demand imbalances in both volume and mix• Performed production leveling using Industrial engineering optimizing techniques.• Performed inventory optimization by reducing WIP and eliminating obsolete parts from inventory.• Performed bottleneck management and implemented effective capacity management and production monitoring system.• Maintained WIP accuracy of 90% and reduced Work Order aging.• Performed simulated cost roll ups for various assemblies.• Developed cost model for a strategic sourcing project which has potential savings of $70K for the contract. Show less

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  Microsoft

  Apr 2019 - May 2024

  • Senior Product Manager

    Apr 2023 - May 2024

  • Program Manager 2

    Apr 2019 - Mar 2023