1. Rajesh B Wankhade
: 0240-2475933 / 09503050544
: rajeshbwankhede@gmail.com
~ STRATEGIC PLANNING ~ PRODUCTION OPERATIONS ~ PROCESS OPTIMIZATION ~
Result oriented professional with proficiency in running successful method-oriented operations & taking initiatives for
business excellence
Industry Preference: Automobile / Manufacturing
Location Preference: Pune / Nasik /Chakan
COMPETENCY MATRIX
Production Operations
Strategic Planning
Process Optimization
Maintenance Operations
Project Execution & Control
Training & Development
Robotics & Automation
Team Management
PROFILE SNAPSHOT
 A dynamic professional with 28 years of experience in steering initiatives towards
achievement of organizational goals with chief responsibilities pertaining to
Production & Maintenance Operations
 Hands on experience in implementing Total Productive Maintenance and improving
quality of machines, equipment & processes
 Effectively carried out Functional & Reliability Tests on various product
samples & implemented number of strategies to enhance product functions &
received zero customer complaints for export market
 Successfully introduced new models like Pulsar-135/150, Boxer’s Family &
all Discover New Family Models
 Instrumental inrecommending modifications to minimizeescalations & rejections in
the production process; realizing operational efficiencies and controlling costs &
cycle time
 Strong leader with excellent motivational skills to sustain forward growth
momentum while motivating peak individual performance from team members
A R E A S O F E X P E R T I S E
 Analyzingand mapping existingprocesses to the desired levels (GAPAnalysis) and suggestingappropriate business solutions to
achieve higher levels of efficiency and effectiveness
 Documenting various MIS reports for the top managements perusal & assisting in critical decision making
 Supervising & controlling production parameters for ensuring product quality in compliance with the given standards
 Establishing strong business rapport with the suppliers; managing day‐to‐day supplier performance for achieving service,
cost, delivery and quality norms
 Liaising with the team members to provide guidance on process development, detailing on quality requirements and
finalization of quality plans
 Working with a strong vigilance for any potential hazards by performing regular inspections and ensuring adherence to
health & safety parameters as per the rules & regulations
O R G A N I Z A T I O N E X P E R I E N C E
Aug’87 – June’15 Bajaj Auto, Ltd., Aurangabad
Growth Path:
April’05 – June’15 Senior Manager (Motorcycle Division) – Paint, ED and Fuel Tank Assembly Shop
Team Size: 10 Managers, 4 Section Managers, 16 Group Leaders & 300 Workmen
Nov’91 – Mar’05 Maintenance Manager (Motorcycle & 3WH Division) – Paint, ED, Electroplating, Vehicle Assembly
Shop & LPG Installations
Team Size: 4 Assistant Managers, 2 Section Managers, 28 Fitters & 8 Electricians
Aug’87 – Oct’91 Assistant Manager (Industrial Engineering Department) Motorcycle Division & 3WH Division
Key Result Areas:

2. As Senior Manager (Motorcycle Division)
 Devising strategic plans for entire Paint, ED Process & Assembly Shop Operations and implementing improvement projects
 Aligning the teams with company vision and objectives, aligning resources to achieve the goals.
 Developing and engaging the people, bring positive change, generate new ideas for continuous improvement.
 Achieving Daily and monthly targets of Domestic & Export Markets
 Liaising with:
o Vehicle Frame, ABS Part, Auto components, Paint & Decal Suppliers
o Engineering & Component Development Department for improvement activities
 Serving as:
o Core Member of Plant Steering Committee
o Coordinator for TPM, ISO 14001 & OHSAS (Environment Management Systems)
As Maintenance Manager (Motorcycle & 3WH Division)
 Spearheaded equipment maintenance of Paint, ED, Electroplating, Vehicle Assembly Shop & LPG Installations
 Executed preventive maintenance schedules, Time based maintenance & Condition based activities for:
o France Make PLC controlled SAMES Painting Systems, High Speed Magnetic Turbines & Bells
o Conveyors - Econ Super, Belt Conveyors, Slat Conveyors, Gear Boxes & Drives
o Thermax Aquatherm Boilers, US Make Maxon Burners, Oertli Make Burners & Heating Ovens
o Heat Exchangers – Plate & Coil Type and Pumps - Centrifugal, Reciprocating & Gear Pumps
o Atlas Make Reciprocating & Screw Type Compressors
o LPG Installations, Firefighting Systems & Incinerators Jig Burning Ovens
o Air Replacement Plants, Exhaust & Pneumatic Systems
o Nut Runners, Number Punching Machines, Pneumatic & Hydro Pneumatic Tools
o Paint Sludge Incinerators & Centrifuges
o Electroplating Wagons & Gear Boxes.
o Implemented concept of RCM for LPG system & boilers where high degree of function & safety is essential.
Assistant Manager (Industrial Engineering Department)
 Conducted time & work studies for press, assembly, machining operations.
 Planned multiple activity charts, manpower calculations, capacities, equipment &
manpower utilization
 Ensured adherence to International Labor Organization (ILO Systems)
Significant Accomplishments:
 Received Excellence Award consistently from 2006 to 2012 for best performance.
 Received 1st prize for presentation at IMTMA for Best Asset Utilization in 2008
 Presented 45 Kaizens to TPM Guide which resulted in quality & cost benefits
 Served as Core Member in JIPM audit and received TPM Excellence Award
 Successfully nominated to study upgraded SAMES Painting Equipment at France 2014
K E Y P R O J E C T S H A N D L E D
Process Improvement Projects
Painting Lines Productivity:
Kaizen Implementation:
 Introduced Tectallis Process in place of Phosphating.
 Optimized Bell Painting Parameters for better DFT
 Reduced Pitch from 0.8 to 0.6 meters
 Increased Conveyor Speed from 1.5 to 2.4 mts/min
 Changed Oven Duct Design for Increased Conveyor Speed
Results Obtained:
 Improved Components/Hanger by 33% and Painting Line
capacity from 3000 to 8000 components/day
 Cost saving of instaling new painting line is eliminated.
Decal Application Cell:
 Implemented:
o Conveyorized Decal Application & Robotic Decal
Application which resulted in P,Q,C benefits to the
company

3. o Modifications in Decal Profiles for ease of applications
o Multi Model Fixtures for Decal Application which resulted in flexibility & setup time reduction
o Implemented robotic decal application process for fatigue reduction and productivity improvement.
Fuel Tank Assembly Cell:
 Implemented conveyorized Fuel Tank Assembly Process.
 Implemented kit bin concept for designing best assembly layout.
 Implemented online Leakage Testing Method for Fuel Tank Assembly which has benefitted in Steam lining the process
 Improved Line Balancing by 20% by Breaking Bottleneck Operations
 Reduced manpower by 30% using ECRS Concept and LCA.
Quality Improvement Projects
Dust & Dirt Defect Reduction:
 Implemented Dust Count Exercise & provision of Freudenberg Filters which reduced dust & dirt defect by 10%
 Made use of:
o Discs on Painting Hangers to prevent dust falling from Moving Conveyor and Non-metallic Indexing Guides to repel
Paint Deposition
o Air Curtains, Double Doors & De Ionizing Blowers to prevent dust and high pressure Air Knife to clean the object
Orange Peel Defect:
 Maintained:
o Humidity in the range of 60 to 80 RH by providing Fogging Nozzles ( a new concept)
o Temperature of paint kitchen by Chilling Unit
 Improved RA value of surface from 1.2 to 0.8 by providing 3M polishing equipments.
 Controlled viscosity by providing online Viscometer.
 Installed BYK Wave Scan Meter for controlling DOI values.
Paint Peel Off Defect:
 Made use of:
o PTFE Coated Screws for Fuel Tank Cap Fitment to arrest Petrol Fumes
o Notch for 0 Ring to avoid Dislocation & arrest Petrol Fumes
 Liaised with suppliers and increased petrol resistance of Paint Film
 Introduced Burr Free Washers of Fuel Cap Fitment
Fuel Tank Assembly Defects – Fuel Leakage from Fuel Tank:
 Changed:
o Differential Method of Leak Test to Direct Leak Test which has eliminated defects.
o Specifications of Water Dip Test from 15 to 10 PA/10 sec
o Supply Mode of Fuel Gauge 0 Ring to avoid deformation
 Made use of:
o Spigot in Fuel Cock body for perfect sealing.
o Illumination System for Water Dip Test Equipment for better inspection
Cost Reduction Projects
Paint Cost Reduction:
 Made use of High Transfer Efficiency Bells for better atomization & more coverage
 Reduced wastage by minimizing gap between components
 Planned alternate source of M/s Nippon to compete with KNPL & APPG
Energy Cost Reduction:
 Eliminated IR Heating Oven of decal by using Channelized Decal Liners
 Made use of stop mode for Air Replacement Blowers & Exhaust Blowers in recess time
LPG Cost Reduction:
 Reduced hanger weight to minimize load in oven
 Made use of Solar Concentrator to Heat Pretreatment Chemicals
 Replaced IR Heating Oven with LPG Fired Oven at Fuel Tank Dry Off Stage
Waste Reduction by 6R Principles – Environment Improvement:
 Eliminated Phosphate Sludge Generation completely at pre-treatment process
 Used Centrifuge System to reduce water content of Paint Sludge

4.  Collected Waste Thinner & re used the same which resulted in cost & impact on environment.
Safety Improvement Projects
 Made use of:
o Remote Operated Valve & Earth Monitoring System in LPG installations
o Shut Off Valves in Paint Kitchen Pneumatic System
o Anti-static Tubing & Conductive Matting in Paint Kitchen
P R O F E S S I O N A L Q U A L I F I C A T I O N S
1987 B.E. in Mechanical Engineering from Government College of Engineering, Amravati University
1989 Diploma in Business Management from College, Aurangabad University
Other Course:
 Completed course in Production Management from JIPM, Japan in 2011 (Delivered 2 hours lecture on “Jitzu Hozen
Activities” as requested by JIPM guide)
I T S K I L L S
 Sound knowledge of MS Office Suit & Microsoft Windows
P E R S O N A L D E T A I L S
Date of Birth : 28th March 1964
Languages Known : English, Hindi & Marathi
Address : “Trinity “Plot No 8, N2/A Sadashiv Nagar, CIDCO Jalna Road, Aurangabad – 431001, Maharashtra