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Gaurav MakanProduction Manager at Shivam Autotech Ltd.

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“Visinory leader for Manufacturing Graduate ” Seeking High level assignments in Production
Operations, Strategy planning, Process Enhancement, Value–Engineering, and QMS
Implementation with an organization of repute
Gaurav Makan
gaurav_makan@yahoo.com
09810627798
A competent Lean manufacturing professional with over 12.8 years of qualitative (Automobile) experience in
Production Operations Business Excellence ,Strategy planning, Production Planning & Control, Process
Enhancement thru TPM, TPS & Lean Manufacturing, Value–Engineering, and QMS Implementation. Presently
associated with Shivam Autotech Ltd. as Production Head , also heading Business excellence for
Whole Shivam Group.
( April -2013 ~ Present) .
Academic Credentials
Qualification Institute BoardUniversity Year
Visinory Leaders For
Manufacturing
C.I.I, J.I.C.A 2009 ~ 2010
PGDBA (Operations) Symbiosis Centre of
distance learning
Pune 2005
B.E (Mechanical) Dronacharya college of
engineering
Gurgaon 2003
Diploma in Mechanical
Engg.
Govt. Polytechnic Jhajjar 2000
Competency Forte
Operations
 Production Management
o Managing overall production operations with a view to ensure timely accomplishments of
production targets within the time and cost parameters.
o Overseeing effective resource planning for optimizing man & machine utilization, reducing
wastes for enhancing productivity and profitability through V-Map, MPS & TPS techniques..
o Devising & effectuating SOP’s as per documents and records.
o Achieving stretched targets in terms of PQCDSM as well as involved in knowledge sharing
through training programs & seminars.
o Co-ordinating & Leading TPM activity all across Shivam Group of Companies in all Three
Locations.
o Heading Business Excellence Cell in whole Shivam group of Companies to transform the
manufacturing with best practices.
o Leading Jishu Hozen Pillar for Improving O.E.E
o Working as a Head of Kobetsu kaizen Pillar.
 Production Planning & Control
o Heading PPC function in Binola facility,
o Improved Machine utilization by working on Value stream Process of Runners, Repeaters and
strangers in Production.
o Reduce Inventory in the Plant of 1 Cr INR.
o Working on Implementation of Product based Layout Planning.
 Quality Management
o Maintaining quality standards for in house machined parts, ensuring stringent adherence to
quality standards, norms & practices, identifying gaps and taking corrective action.
o Monitoring adherence to quality standards of ISO, SQC and POKA YOKA thereby exceeding
quality, cost and productivity targets for production line.
o Overseeing implementation of lean manufacturing concepts and executing various projects
for improvement in quality. & with quality circles.
 Value Engineering/ Process Development
o Overseeing process enhancement/ optimization initiatives with the view to increase efficiency
of machinery by process modification and eventually reducing costs.
o Analyzing problems and undertaking modifications, processes and change of Machines to
enhance productivity and reduce product rejections/ rework.
o Identifying the bottleneck operations & implementation of LCA (Low cost automation) to
improve productivity and implementation of TPS techniques.
 Maintenance Management
o Scheduling and planning predictive, preventive and Shutdown maintenance jobs with key
focus on spares availability and root cause analysis including budgeting and cost control
activities.
o Monitoring plans/schedules to start maintenance activities and achieve plant targets,
implementing maintenance systems & keeping data for up gradation of plant.
Business Excellance
 Lean Manufacturing
o Trained under lean manufacturing Japanese Consultant , Hamamashi Kato & Prof.
Furuhashi Takeyuki for productivity improvement through Value Stream Mapping.
o Trained on” Toyota Production System” from TKML..
o Extensively trained on POKA-YOKA mistake proof systems.
o Presently running a Lean Project along with Bosch team both for Binola Facility and
forthcoming Project in Hosur Karnataka.
o Heading Jishuken activity within company as well as at supplier end.
o Trained on Low cost automation techniques
o Trained and conducted Micro motion study analysis trainings for methods improvement and
work Ergonomics.
o Proven Layout designer with operator friendly design concepts.
o Well versed with TS16949 system, APQP methodology.
o Certified Internal Auditor for TS16949 & IMS standards.
 Strategic Management
o Formulating pre-planned developmental strategies for achievement of goals and targets by
identifying & developing new avenues for long term growth.
o Conceptualizing & implementing Systems & operating procedures to optimize resource/capacity
utilization in production operations.
o Leading the Project team in development of Capacity expansion Projects.
o Leading Layout improvement activity to enhance Man / Machine Capacity. Converting Present
Process based layout to Product based layout, to maintain single piece flow mechanism.
o Leading Value Stream Mapping Projects in all 3 manufacturing locations to improve Inventory
turnover Ratio and streamlining the inventory flow.
 Total Productive Maintenance
o Heading TPM work at Gurgaon and Haridwar location under the guidance of TPM club of India
thru C.I.I.
o Facilitating and co-ordinating TPM activity in both Manufacturing units.
o Heading Kobetsu Kaizen Pillar at Binola Facility.
o Group Co ordinator for Kaizen activity. Got the best Kaizen award for reduction in Tool cost by 20
% in last two consecutive years.
Job Responsibilities;
 Presently heading operations with a view to ensure timely accomplishments of production targets within
the time and cost parameters as per the Marketing Commitments.
 Heading Business Excellence cell in Shivam group.
 Co-Ordinating & Leading TPM, Kaizen and Lean Manufacturing activities all across Shivam Group of
companies.
 Directed and supervised implementation of Lean manufacturing concepts Thru Value Stream Mapping.
 Instrumental in generating savings up to 12 Lacs /annum by manpower rationalization and reducing the
workforce by 33 per day in 1 line by implementing Lean Manufacturing (Toyota Production System) in
Boss Rotor Line.
 Inventory reduction 1.Cr to 50 lacs by implementing just in time and KANBAN system.
 Implemented multi – machine operation concept layouts for Machining & Assembly, to suit to wide
fluctuations of market demand / TACT time there by reduced the man power from 382 to 302
 Reduced rejection cost / per kit by 60% by working on Cost Pareto analysis & Quality circle activities
,overall savings 15 lacs PA
Notable Highlights:-
At Gear Shop
 Distinction of increasing productivity by 60% by the implementation of Multi Hobbing instead of single
part Hobbing Saved Rs 4.8 lacs per annum saved in terms of manpower.
 Major role player in minimizing processes rejections, waste elimination by saving Rs 7 Lacs Per Annum.
At Machine shop
 Attained elimination of Hydraulic oil wastage by establishing & assuring Millipore values of individual parts
& as well as lubrication oil by process improvements resulted in savings of Rs. 9 Lakhs per annum.
 Distinction of attaining productivity improvement of for more than 35% and saving Rs 22 Lakhs per
annum in Shaft Machining line .
 Increase capacity by 45 % using Jishuken techniques & save 60 lacs/ annum.
At Manufacturing Department
 Completed Value Stream Mapping project and reduced material travel by 60 % and reduced lead time by
half and cost saving upto 18 lacs /annum
 Undertook Micro motion study with Mr. Kato (consultant) by methods improvement, single piece flow,
Max. Single day inventory etc; this resulted in process time reduction from 78 min to 64 min and the
productivity improved by 18 % by this Rs 1.8 lacs saved per annum in terms of manpower.
 Handled De-bottlenecking from Cnc Machining line achieved productivity improved to 40%.
 Executed 10 LCA projects, 5 electrical & 20 mechanical POKAYOKA to reduce operator fatigue and to
improve operator morale.
Past Experience :-
Earlier associated with (Somic Zf components Ltd.)Previously Known as Sona Somic
Lemforder Components Ltd ( Feb-2006 ~ Apr-2013). as Manager directing overall operations
as Production Head. Instrumental in taking cost saving initiatives and undertaking trouble shooting & de-
bottlenecking of the process/equipment to enhance productivity. Certified MPS & TPS applicator. Distinction of
implementing around 2500 Kaizen across the plant which resulted in PQCDSM. An astute leader with ability to
motivate subordinates in optimizing their performance levels and possesses excellent analytical,
organizational & interpersonal skills. Passionate to move to complicated areas to strengthen the operations
with innovative, analytical approach with productive relationships for team building to achieve stretched
targets.
Achievements :
a. Saved approx. 30 million INR from Project Nav Nirman thru
rationalization of layouts and introduction of new techniques.
b. Lead TPS and MPS Projects across the plant.
c. Co Ordinated Schedule B activities in TPM Health Checkup & TPM
Excellence audits, also worked as Dy. Leader for Jishu Hozen and K.K
Pillar.
d. Value stream Mapping project on Suspension welding & assy. Lines .
MOTHERSON SUMI SYSTEM LTD (AUG’04 – FEB-06)
Production Engineer (Machine Shop) from Aug’04.
In Machine Shop (includes processes like special cutting and crimping)
Motherson Sumi Systems Limited is a 6000 Cr. turnover Company having the certification of ISO-9001,
QS-9000 and ISO 14001 for its quality and environment systems. Company is proceeding to world first
manufacturers of Wiring Harness with the collaboration of Sumitomo wiring systems (SWS) Japan and Nisho
IWAI Corp. Japan.
Achievements:
1) Developments of the High Tension Cord Line
2) Projects based on Maruti Production System (MPS)
3) MPS Projects on Line resulting saving of the 5 manpower, Reduction in set up time
4) Value Stream Mapping of the cutting and crimping machines.
Benda Amtek Ltd. (June’03-August’04)
Worked as Production Engineer in MC shop (Fly Wheel Section). Done CNC programming and job setting and
setup planning.
Projects:
1) Developments of the G.M. Tavera Flywheel
2) Took part in development of adopter plate clutch for New Holland.
Training Course:
2. Maruti Production System, TIE (Total industrial engg.), WSTC, T.P.S
Personal Details
Date of birth : 19.05.1982
Address : House No:- 559/21, Lane No-8, Madan Puri , Gurgaon, Haryana,(122001).
Languages known : Hindi, English, Punjabi.
Marital status : Married
Children : One ( Daughter)
Date :- Gaurav Makan
Training Course:
2. Maruti Production System, TIE (Total industrial engg.), WSTC, T.P.S
Personal Details
Date of birth : 19.05.1982
Address : House No:- 559/21, Lane No-8, Madan Puri , Gurgaon, Haryana,(122001).
Languages known : Hindi, English, Punjabi.
Marital status : Married
Children : One ( Daughter)
Date :- Gaurav Makan

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Gauravcv

  • 1. “Visinory leader for Manufacturing Graduate ” Seeking High level assignments in Production Operations, Strategy planning, Process Enhancement, Value–Engineering, and QMS Implementation with an organization of repute Gaurav Makan gaurav_makan@yahoo.com 09810627798 A competent Lean manufacturing professional with over 12.8 years of qualitative (Automobile) experience in Production Operations Business Excellence ,Strategy planning, Production Planning & Control, Process Enhancement thru TPM, TPS & Lean Manufacturing, Value–Engineering, and QMS Implementation. Presently associated with Shivam Autotech Ltd. as Production Head , also heading Business excellence for Whole Shivam Group. ( April -2013 ~ Present) . Academic Credentials Qualification Institute BoardUniversity Year Visinory Leaders For Manufacturing C.I.I, J.I.C.A 2009 ~ 2010 PGDBA (Operations) Symbiosis Centre of distance learning Pune 2005 B.E (Mechanical) Dronacharya college of engineering Gurgaon 2003 Diploma in Mechanical Engg. Govt. Polytechnic Jhajjar 2000 Competency Forte Operations  Production Management o Managing overall production operations with a view to ensure timely accomplishments of production targets within the time and cost parameters. o Overseeing effective resource planning for optimizing man & machine utilization, reducing wastes for enhancing productivity and profitability through V-Map, MPS & TPS techniques.. o Devising & effectuating SOP’s as per documents and records. o Achieving stretched targets in terms of PQCDSM as well as involved in knowledge sharing through training programs & seminars. o Co-ordinating & Leading TPM activity all across Shivam Group of Companies in all Three Locations. o Heading Business Excellence Cell in whole Shivam group of Companies to transform the manufacturing with best practices. o Leading Jishu Hozen Pillar for Improving O.E.E o Working as a Head of Kobetsu kaizen Pillar.  Production Planning & Control o Heading PPC function in Binola facility, o Improved Machine utilization by working on Value stream Process of Runners, Repeaters and strangers in Production. o Reduce Inventory in the Plant of 1 Cr INR. o Working on Implementation of Product based Layout Planning.
  • 2.  Quality Management o Maintaining quality standards for in house machined parts, ensuring stringent adherence to quality standards, norms & practices, identifying gaps and taking corrective action. o Monitoring adherence to quality standards of ISO, SQC and POKA YOKA thereby exceeding quality, cost and productivity targets for production line. o Overseeing implementation of lean manufacturing concepts and executing various projects for improvement in quality. & with quality circles.  Value Engineering/ Process Development o Overseeing process enhancement/ optimization initiatives with the view to increase efficiency of machinery by process modification and eventually reducing costs. o Analyzing problems and undertaking modifications, processes and change of Machines to enhance productivity and reduce product rejections/ rework. o Identifying the bottleneck operations & implementation of LCA (Low cost automation) to improve productivity and implementation of TPS techniques.  Maintenance Management o Scheduling and planning predictive, preventive and Shutdown maintenance jobs with key focus on spares availability and root cause analysis including budgeting and cost control activities. o Monitoring plans/schedules to start maintenance activities and achieve plant targets, implementing maintenance systems & keeping data for up gradation of plant. Business Excellance  Lean Manufacturing o Trained under lean manufacturing Japanese Consultant , Hamamashi Kato & Prof. Furuhashi Takeyuki for productivity improvement through Value Stream Mapping. o Trained on” Toyota Production System” from TKML.. o Extensively trained on POKA-YOKA mistake proof systems. o Presently running a Lean Project along with Bosch team both for Binola Facility and forthcoming Project in Hosur Karnataka. o Heading Jishuken activity within company as well as at supplier end. o Trained on Low cost automation techniques o Trained and conducted Micro motion study analysis trainings for methods improvement and work Ergonomics. o Proven Layout designer with operator friendly design concepts. o Well versed with TS16949 system, APQP methodology. o Certified Internal Auditor for TS16949 & IMS standards.  Strategic Management o Formulating pre-planned developmental strategies for achievement of goals and targets by identifying & developing new avenues for long term growth. o Conceptualizing & implementing Systems & operating procedures to optimize resource/capacity utilization in production operations.
  • 3. o Leading the Project team in development of Capacity expansion Projects. o Leading Layout improvement activity to enhance Man / Machine Capacity. Converting Present Process based layout to Product based layout, to maintain single piece flow mechanism. o Leading Value Stream Mapping Projects in all 3 manufacturing locations to improve Inventory turnover Ratio and streamlining the inventory flow.  Total Productive Maintenance o Heading TPM work at Gurgaon and Haridwar location under the guidance of TPM club of India thru C.I.I. o Facilitating and co-ordinating TPM activity in both Manufacturing units. o Heading Kobetsu Kaizen Pillar at Binola Facility. o Group Co ordinator for Kaizen activity. Got the best Kaizen award for reduction in Tool cost by 20 % in last two consecutive years. Job Responsibilities;  Presently heading operations with a view to ensure timely accomplishments of production targets within the time and cost parameters as per the Marketing Commitments.  Heading Business Excellence cell in Shivam group.  Co-Ordinating & Leading TPM, Kaizen and Lean Manufacturing activities all across Shivam Group of companies.  Directed and supervised implementation of Lean manufacturing concepts Thru Value Stream Mapping.  Instrumental in generating savings up to 12 Lacs /annum by manpower rationalization and reducing the workforce by 33 per day in 1 line by implementing Lean Manufacturing (Toyota Production System) in Boss Rotor Line.  Inventory reduction 1.Cr to 50 lacs by implementing just in time and KANBAN system.  Implemented multi – machine operation concept layouts for Machining & Assembly, to suit to wide fluctuations of market demand / TACT time there by reduced the man power from 382 to 302  Reduced rejection cost / per kit by 60% by working on Cost Pareto analysis & Quality circle activities ,overall savings 15 lacs PA Notable Highlights:- At Gear Shop  Distinction of increasing productivity by 60% by the implementation of Multi Hobbing instead of single part Hobbing Saved Rs 4.8 lacs per annum saved in terms of manpower.  Major role player in minimizing processes rejections, waste elimination by saving Rs 7 Lacs Per Annum. At Machine shop  Attained elimination of Hydraulic oil wastage by establishing & assuring Millipore values of individual parts & as well as lubrication oil by process improvements resulted in savings of Rs. 9 Lakhs per annum.  Distinction of attaining productivity improvement of for more than 35% and saving Rs 22 Lakhs per annum in Shaft Machining line .  Increase capacity by 45 % using Jishuken techniques & save 60 lacs/ annum. At Manufacturing Department
  • 4.  Completed Value Stream Mapping project and reduced material travel by 60 % and reduced lead time by half and cost saving upto 18 lacs /annum  Undertook Micro motion study with Mr. Kato (consultant) by methods improvement, single piece flow, Max. Single day inventory etc; this resulted in process time reduction from 78 min to 64 min and the productivity improved by 18 % by this Rs 1.8 lacs saved per annum in terms of manpower.  Handled De-bottlenecking from Cnc Machining line achieved productivity improved to 40%.  Executed 10 LCA projects, 5 electrical & 20 mechanical POKAYOKA to reduce operator fatigue and to improve operator morale. Past Experience :- Earlier associated with (Somic Zf components Ltd.)Previously Known as Sona Somic Lemforder Components Ltd ( Feb-2006 ~ Apr-2013). as Manager directing overall operations as Production Head. Instrumental in taking cost saving initiatives and undertaking trouble shooting & de- bottlenecking of the process/equipment to enhance productivity. Certified MPS & TPS applicator. Distinction of implementing around 2500 Kaizen across the plant which resulted in PQCDSM. An astute leader with ability to motivate subordinates in optimizing their performance levels and possesses excellent analytical, organizational & interpersonal skills. Passionate to move to complicated areas to strengthen the operations with innovative, analytical approach with productive relationships for team building to achieve stretched targets. Achievements : a. Saved approx. 30 million INR from Project Nav Nirman thru rationalization of layouts and introduction of new techniques. b. Lead TPS and MPS Projects across the plant. c. Co Ordinated Schedule B activities in TPM Health Checkup & TPM Excellence audits, also worked as Dy. Leader for Jishu Hozen and K.K Pillar. d. Value stream Mapping project on Suspension welding & assy. Lines . MOTHERSON SUMI SYSTEM LTD (AUG’04 – FEB-06) Production Engineer (Machine Shop) from Aug’04. In Machine Shop (includes processes like special cutting and crimping) Motherson Sumi Systems Limited is a 6000 Cr. turnover Company having the certification of ISO-9001, QS-9000 and ISO 14001 for its quality and environment systems. Company is proceeding to world first manufacturers of Wiring Harness with the collaboration of Sumitomo wiring systems (SWS) Japan and Nisho IWAI Corp. Japan. Achievements: 1) Developments of the High Tension Cord Line 2) Projects based on Maruti Production System (MPS) 3) MPS Projects on Line resulting saving of the 5 manpower, Reduction in set up time 4) Value Stream Mapping of the cutting and crimping machines. Benda Amtek Ltd. (June’03-August’04) Worked as Production Engineer in MC shop (Fly Wheel Section). Done CNC programming and job setting and setup planning. Projects: 1) Developments of the G.M. Tavera Flywheel 2) Took part in development of adopter plate clutch for New Holland.
  • 5. Training Course: 2. Maruti Production System, TIE (Total industrial engg.), WSTC, T.P.S Personal Details Date of birth : 19.05.1982 Address : House No:- 559/21, Lane No-8, Madan Puri , Gurgaon, Haryana,(122001). Languages known : Hindi, English, Punjabi. Marital status : Married Children : One ( Daughter) Date :- Gaurav Makan
  • 6. Training Course: 2. Maruti Production System, TIE (Total industrial engg.), WSTC, T.P.S Personal Details Date of birth : 19.05.1982 Address : House No:- 559/21, Lane No-8, Madan Puri , Gurgaon, Haryana,(122001). Languages known : Hindi, English, Punjabi. Marital status : Married Children : One ( Daughter) Date :- Gaurav Makan