Anil Kumar

Experience

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  Quality Needles Pvt. Ltd.

  May 2003 - Jan 2005

  Production Supervisor
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  Shriram Pistons & Rings Ltd.

  Aug 2005 - Feb 2007

  Shift in-charge of Engine Valve section
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  DENSO

  Feb 2007 - Aug 2012

  Engineer

   Alternator section coordination .   Oversaw production, trouble shooting & inventory control management while planned & conceptualized strategies for accomplishment of production targets within specified time/quality parameters. Monitored defects & performed root cause analysis. As an active member of quality circle aimed at continuous improvement & ensured implementation of poke yoke activities for Improvement. Implemented Kanban, Andon, Kakotora, Naze Naze analysis, 5G, 5S and modern rejection control tools on the shop floor.  Accountable for achieving single digit PPM at customer end & 50% reduction in field return & assembly rejection (with zero visual defects). Arranged training for workmen & created awareness about total productivity management system. Prepared the line rejection and reviewed corrective action.  Handled receipt and issue of all types of spares, hold parts, indirect consumables with physical verification as per production plan & maintained proper computerized documentation daily.  Accountable for DDK reduction, productivity improvement, scrap & indirect consumable cost reduction as a member of the Production Improvement Cell. Planned elimination of major repetitive defects for reduction of repair cost. Monitored customer complaint and took countermeasures to make it at zero level, to reduce the rejection cost.  Oversaw the overall function of production/assembly related domestic direct/indirectconsumable purchasing. Show less

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  Renault-Nissan-Mitsubishi

  Aug 2012 - Jun 2014

  Asst. Manager in Trim & Chassis line

   Responsible for daily production control, target meeting with high focus on quality, taking counter measures for line defects & their implementation. Monitoring process of continuous improvement (kaizen) in model mix-up for achieving substantial reduction in component defects and assembly defects by TPM, 5s implementation.Maintaining QCDMS targets on line. Zone wise time study based on model ratio or customer requirement to achieve daily production target . Effectively ensuring materials management and inventory control to maintain smooth flow of materials with minimum inventory holding. Executing cost saving techniques / measures and modifications to achieve substantial reduction in various expenditures. Ensuring frequent quality improvements, productivity improvements, setup time reduction, multi machines balancing and actively responsible for meeting day-to-day production target. Improving operational efficiency by enhancing capacity utilization, reducing rejections and non-value added activities and logistics improvement. Demonstrating superior people management skills and facilitating cross-functional team formation to reduce and solve customer complaints. Spearheading productivity improvement activities required for producing components while controlling the cost and maintaining world class quality. Carrying out the task of administering production weekly output to overcome the pitfalls in quality, quantity & delivery schedules. Actively involved in devising manpower, machinery and material planning and scheduling them to meet the delivery requirements. Successfully mentoring and guiding the subordinates regarding the technical & managerial problems. Conducting operator training for new models and current set-up on regular basis. Ensuring that all the machines are meeting the specifications of quality control measures in compliance to the international standards. Show less

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  Faurecia

  Jul 2014 - Jan 2023

  UAP Manager

   Manage the effective operation of the UAP Team, as well as HR issues for team members.  Follow production plans, as well as Group standard processes; assure feasibility of production plans. Achieve financial targets: prepare and present the UAP budget; manage the actual production costs based on "ideal" costs; maintain product margin, and monitor serial productivity (labor level, material consumption, etc.). Manage the UAP team: assure appropriate staffing, maintain working environment according to Group Health, Safety & Environment (HSE) standards , detect and advise training needs, share information (transparency), participate in career management initiatives, etc. Serve as official plant representative to the customer: meet established customer specifications concerning cycle time, delivery, quality, quantity and costs; implement preventative and corrective measures in the production process to assure that customer demands are properly met; coordinate with client's quality team to meet all customer standards. Implement action plans in order to improve functionality/productivity and to obtain program and Group objectives; make necessary corrective adjustments. Participate in the creation of Production System Efficiency (PSE) projects. Coordinate resource planning with Industrial Engineering department concerning stocks, equipment, staffing, activities, etc. Maintain dashboard indicators/status reports to monitor lead time, supply-chain targets, HSE performance, etc. Show less

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  Hero Motors

  Jan 2023 - Dec 2024

  Plant Head

  Plant profitability improvement via waste reduction and row material cost reduction.Lean system implement and monitor daily routine. Training to all key departments.New product development and supplier development.Inventory reduction , Pull flow system implement.Manpower reduction with line efficient balancing and maximum output with real time production monitoring.Lean manufacturing system implementation and training to respective departments.

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  TM Automotive Seating Systems Pvt. Ltd.

  Dec 2024 - now

  Plant Head

  - Strategic LeadershipDevelop and execute the plant’s operational strategy to align with organizational goals.Drive continuous improvement initiatives to enhance productivity and efficiency.Lead and mentor cross-functional teams, fostering a high-performance culture.- Operations & Production ManagementEnsure smooth plant operations while meeting production targets and quality standards.Optimize resource utilization, including manpower, machinery, and materials.Implement lean manufacturing and Six Sigma principles to improve efficiency.- Profitability & Cost ControlDrive cost reduction initiatives without compromising quality and safety.Monitor and improve key performance indicators (KPIs) such as OEE, rejection rate, and downtime.Develop budgets and control operational expenses.- Quality & ComplianceEnsure adherence to quality standards (ISO, TS, IATF, etc.) and customer requirements.Conduct regular audits and implement corrective actions to minimize defects.Drive a culture of quality awareness among employees.- Safety & SustainabilityEnsure compliance with workplace safety regulations and EHS (Environment, Health, and Safety) policies.Implement risk assessment and hazard prevention measures.Promote sustainable manufacturing practices.- People Management & DevelopmentLead, train, and motivate plant personnel to maximize productivity and engagement.Foster a culture of teamwork, accountability, and continuous learning.Handle workforce planning, recruitment, and performance management.- Stakeholder ManagementCollaborate with senior management, suppliers, and customers to align production with business objectives.Maintain good relations with local authorities and regulatory bodies.Ensure smooth coordination between different departments (Production, Quality, Maintenance, Logistics). Show less