Vijay Kumar.docx

VIJAY KUMAR Email:[email protected]; ~Mobile:+91-7838200098,7838242473

Industrial Engineer/Lean Six sigma Cost-Consciousness and analytical with history of success in optimizing Production processes and quality in fast-paced manufacturing environments. Increase productivity, Quality, and profitability through keen data analysis and process design; significantly improve operations by recommending methods for improvements and providing efficient resolution to production issues. Identifying opportunities for honing safety standards and maximizing ROI, Excel at completing projects on time and within Budget. Implementing training programs and supporting Lean initiatives/facility/costing. Proven ability to determine and establish the most efficient methods for maximum utilization of production facilities and personnel; as well as assisting line management in the development and implementation of standard procedures.

Areas of Expertise Lean Manufacturing – Six Sigma – Value Stream Mapping – Production Planning & control-Just in time – World Class Manufacturing – Kanban – Kaizen – Statistical Process control- Demand Planning – Capacity Planning – Manpower Planning – Layout Improvement – Vendor development – ISO Audits. Career Overview



More than 13 years of experience in Lean Six Sigma, Project planning & Industrial Engineering.



Presently associated with Panasonic AVC Networks India Pvt. Ltd., Noida as DGM-Planning, ISP & Industrial Engineering.



ISP, Demand planning & Negotiating with sales company for Model mix, delivery plan & Inventory management.



Production Planning for the all the products keeping in mind the despatch plan & capacity to optimize our resources.



Issue confirmed sales plan & forecast to concerned department for optimum planning of resources. o



Market study & forecast study based on seasonality and other parameters.

Completed and participated in setting up of new manufacturing plant projects. o

Coordinated and interfaced between the project team and plant personnel in layout design, installation review, process validation, and results analysis for the project, scrap, lines capability, and productivity improvements.



Drive Business Excellence agenda, Integrating vision and strategy, Lean and Six Sigma and learning, to deliver improving and predictable business results.



As a certified Manufacturing Assessor, To Drive WCM philosophy Of Panasonic Production System & to benchmark and share best practices and continuously improve all the functions of the company.



To add value in the analysis of Cost of Poor Quality (CoPQ) data and identify wastes and opportunities for the business to improve in (among others by using Lean principles and methodologies), as well as reporting and celebrating past successes in these areas from a business perspective.



Gained significant exposure towards using various tools like Lean manufacturing, Manufacturing Assessment, Value Stream Mapping, MOST, Six sigma, OEE, 5S, 3R, 5 WHY, etc.



To impart training on 5S & wastes, Motivation to line operators & leaders.



Handling Suggestion schemes, Creating and environment of employee empowerment in bringing improvements



Leading and work with the Process Owners, Engineers and Team Leaders, ensure high standards for safety, quality and productivity.

Significant Achievements: 1) Coordinated and lead the project for productivity improvement in 32 inch TV model by 30% by automation,method study, Line balancing. 2) Manpower Optimization: Role: Leader Tools Used: LCA, Benchmarking, Ergonomics

Fabrication of in-house Battery operated towing cart, which runs on battery, and is used to pull trolleys from material ware house to assembly line. Result: One manpower saved, WIP reduced by 33%. Less fatigue to operator, Technical know and learning of our operators increased. 3) Lead time Reduction (DMAIC Approach): Role: Coordinator Tools: Value stream Mapping, Layout Modification, JIT.Mixed production, SMED We have used Value stream mapping and take actions to reduce WIP to improve our current state and to reach our future state. Delivery cycles of departments have been improved, Mix production for low Inventory, Just in time for 2 hours material storage have been implemented. Layout has been modified to eliminate zig-zag material movement. We have made a straight flow layout. Result: Lead time reduced by 1 day 4) Visual Management: Role: Leader Tools: JIT, Kitting system, Real time monitoring We have introduced scanning system which on one side give real time status of production result Vs. target Plan And on the other side gives an indication to material supply department to supply the material in right quantity at right place and in right time. Result: Better Capacity planning, Better traceability 5) Productivity Up(DMAIC): , Role: Leader Tools used: LCA, Line balancing, Time study, Method study Introduced Pacemaker which runs like a train’s engine pulling the assembly trolleys following it in a ‘O’ type cell. Earlier these trolleys were manually pulled by operators so Approx 2.5 sec per set motion loss was there. Result: Save 40 sec from its standard time. 6) Coordinating and working as liaison for various functional departments from Sales PASAP (Thailand), PAVCI in planning and execution of New Car Audio project. 7) Handled planning, coordination, installation and execution of India’s first Panel assembly line in a clean room maintain 10 ppm dust level. 8) Implementing standard Cell concept. Professional Experience Since Feb’10: Panasonic AVC Networks India Pvt. Ltd., Noida Currently designated as Manager-Production Planning (Industrial Engineering) The Role:  Manufacturing Assessment to visualize manufacturing weaknesses & action plan for improvement.  Analysing validity of additional staffing requests based on year-end targets.  Improving productivity by manpower optimization, LCA, waste reduction.  Developing Vendors for localization of erector system implementation.  To ensure that the process performance is monitored on daily/weekly/monthly bases using KPI boards, and that daily/weekly performance from the cell boards is taken into Pareto stratification and root cause analysis with problem resolution is carried out.  Implemented Product traceability system, AGV-Pacemaker, Battery operated towing cart, Real time production monitoring system  Warehouse space optimization  Value stream Mapping  Continual Innovation activities to support production performance  Making schedule and following up for timely completion of projects  Training to bottom line operators & line supervisor on & wastes,5S,Kaizen  Customization of Packing machine for vertical carton taping Oct’06 Feb’10: Samsung India Electronics Pvt. Ltd., Noida as Engineer (Process Innovation) The Role:  Efficiently enhancing the operations through method study, LOB Improvement, Layout Improvement, Looking after 5S activity, Work flow distribution of line, Kitting system implementing, Best practice report.  Successfully completed four Six sigma green belt projects related to productivity, Line of Balance, Reduction of Jigs cost.  PQ Analysis for optimum resource utilization and higher efficiency  Pareto Analysis for prioritizing Improvement activities for effective time management

 Skillfully maintaining process check sheets, work manuals, process flow charts and managing inventory.  Deft at executing and installing Cell line replace to high cost conveyor line in Mobile phone PBA line.  Pivotally implementing standard time for different model, looking after GMES (Global Manufacturing Execution System) for mobiles, CTV, Monitor.  Simulation study for new line capacity estimation and new model process establishment.  Supervised staff of 15 employees. Overseas Experience And Recognition:                

Awarded MD’s achievement award for improving the productivity by 30% in Dec 2016. Awarded Outstanding Overseas Employee for the Year 2009 in HQ Korea(DEC 2009) Worked as Task force team in implementing Block cell concept in Gumi, Korea Certified Manufacturing Assessor from Panasonic HQ,Japan Published article in Isixsigma magazine in June 2010 Training on Dip soldering(selective soldering) process at Panasonic Malaysia, September 2010. To install dip soldering for the first time in India. Benchmarking of Panasonic at Utsunomiya-Japan ,November 2010 Benchmarking of Panasonic TV & Car Audio systems factory at Bangkok-Thailand, March 2012 Standard Time management Training & Dojo Training at Panasonic ,Utsunomiya-Japan, April 2012 MOST training at PAVCTH, Bangkok-Thailand, October 2012. Dojo Manufacturing Training At Sanyo, Penang (Malaysia), April’13, Dojo Manufacturing training at Panasonic Thailand,June'13 Benchmarking Daihatsu Motors plant & Panasonic Lighting Division,Indonesia,Sep'13 Manufacturing Assessor training At PAVCTH,Bangkok,Oct’2014 Benchmarking of Panasonic Manufacturing division,Malaysia.June’2015. Benchmarking of Panasonic Manufacturing division, Mexico. August’2016. July’05 toOct’06: Thomson Digital, Noida As Engineer (Industrial engineer & QA)

The Role:  Setting production norms & Streamlining work flow of various departments  Manpower Planning & Capacity Planning of the Work force in the Organization  Practicing Kaizen through process improvement, eliminating wasteful activities  Implementation of ISO 9001:2000.ISO internal audits  Facilitator of Quality Circle & Handling Suggestion Schemes.  FMEA, Process mapping through SIPOC, Flow process chart Certifications & Trainings Successfully completed the following trainings to enrich the knowledge base:  Industrial Engineering at Samsung India, Noida by Samsung Innovative Team, Korea.  Black belt certified From Phoenix Quality management services, Gurgaon.  Green Belt certified From Samsung India Electronics Pvt.Ltd.  Advance Cell Line Technology to learn reduce the Model change time and LOB 100%, Certified by Panasonic to impart training on A-Next cell  Certified Manufacturing Assessor from Panasonic Japan  ISO 9001:2000 Internal auditor certification from BSI INDIA training to learn about ISO clauses and auditing methods.  AutoCad 2D for Auto desk IT Skills    

Well versed with MS Office (Excel, Word, Project and Power point), Windows 9X / XP . Auto cad 2D drafting ,Basic knowledge of solid works Minitab MOST Academic Credentials

B.Tech.(Industrial Engineering)in 2005 S.B.S.C.E.T, FEROZEPUR (PUNJAB TECHNICAL UNIVERSITY, JALANDHAR) PGDBM (Production & Materials Mgt.)in 2007 (IIMM, PUNE)

Personal Details Sex: Nationality: Marital Status: Date of Birth: Present Address : Permanent Address: Languages Known:

Date: Place:

Male Indian Married 02ND October, 1983 B-701,Shivalik Homes, Site-c, Surajpur Industrial Area, .Greater Noida A-4, J & K Guest House, Kautilya marg, Chanakayapuri, New Delhi–21 English, Hindi, and Punjabi

(Vijay Kumar)