Bhushan S. Bhapkar is a manufacturing engineer with over 9 years of experience in industrial engineering, process engineering, and project management. He has a Bachelor's degree in Mechanical Engineering and is proficient in various engineering software. Bhushan has worked for companies like Alstom Transport India, JCB India, Mahindra & Mahindra, Kirloskar Brothers, and UMAS implementing lean manufacturing techniques to improve productivity, capacity, and reduce costs. His achievements include increasing production capacity by 30% and saving over 1 crore rupees in labor costs. Currently he works as a Process Engineer at Alstom Transport India.

1. Bhushan S. Bhapkar Email: bhushanbhapkar@gmail.com
Mobile: 9066339181 / 9970746303
PROFESSIONAL ABRIDGEMENT
SKILL SET
• Lean Manufacturing ● Time Study / MOST / Motion Study
• Facility planning (Tooling, Jigs, Fixtures, Machines) ● Line Balancing / Multi Machine Balancing
• Continuous Improvement (Kaizen) ● Resource & Work-force management
• 7QC Tools / Quality Circles ● Plant Safety management (IOSH Certified)
• Toyota Production System (TPS) ● Capital Projects (Capex) Management
• PFMEA / SOP’s / WI’s / Process Sheets ● Layout design
JOB RESPONSIBILITIES
1. Industrial Engineering
 Time Study and Motion Study: Defining cycle time and work content for assembly processes,
machining processes and Process Plants like Paint Shop, Powder Coating Plant and Shot Blast by using
Videography, Production Study and MOST (Maynard Operations Sequence Technique) Study for each
process. Setting of new time standards. Identify and elimination of NVA’s.
 Assembly Line Balancing: Developed assembly line balancing matrixes.
 Multi Machine Balancing: Implemented multi machine balancing module for machine shop.
 Work Force Management: Workforce management on daily, weekly and monthly basis.
 Union Agreement: Lead team to achieve productivity rise in union agreement (2012-15).
 Resource Optimisation: By De-bottlenecking, Layout modifications, Method Improvements.
 Labour Budget: Preparation and monitoring of annual labour budget. Prepare labour budget for 5
year strategic plan.
 Job Contract: Framing, preparation and revision of job contracts for assembly processes, process
plants, kitting activities, maintenance activities etc. Monitoring of job contract cost.
 MIS Report preparations: MIS report preparation for Operator utilisation, Facility utilisation,
Labour cost, Capacity calculations, Job contract cost etc.
2. Process Engineering
 PFMEA: Develop PFMEA’s for each workstation, evaluate and strengthening the overall process.
Thereby preparing the control plan for each workstation.
 Process Sheets: Develop process sheets for all CKD (Complete Knock Down) operations.
 SOP’s – Preparation and Updating SOP’s for NPI (New Product Introduction) and for any PI (Product
Improvement) changes.
 Manufacturing facilities: Providing manufacturing facilities like Fixtures, Tools, Material handling
system and Lifting items for NPI in assembly line, Stores and Process plants.
 Continuous Improvement: Done process improvements by using NVA reduction, continuous
improvement (kaizen), lean manufacturing concepts.
3. Manufacturing Engineering
 Project Management: Capital Budget preparation on the basis of Capacity Enhancement, NPI,
Safety, Quality and Process Improvement. Execution of projects from budget to commissioning of
project.
 Plant Layouts: Re-layouting of plant, assembly line and facilities as per project needs.
Highly skilled Manufacturing Engineer with 9 years of experience in Industrial Engineering,
Process Engineering, Industrialization, New Product Introduction and Capital Projects Management in
Automobile as well as Manufacturing Industries. Demonstrated ability to set/improve new/existing
production norms by using Time study, MOST (Maynard Operation Sequences Technique), Line
Balancing, Continuous Improvements (Kaizen) and Lean Manufacturing. Adept in handling
manufacturing processes implementations/preparing PFMEA’s, Control Plans and SOP’s. Deft in
managing entire gamut of operations with demonstrated leadership qualities; conceptualizing and
effectuating measures in the operating procedures to optimize resource and capacity utilization.

2.  Low Cost Automation: Providing low cost automation solutions to improve PQCDS.
 Green Field Projects: Worked on green field project to set-up of automated TAKT based assembly
line for rollout of pump assembly.
ACHIEVEMENTS
 Alstom Transport India Ltd. -
 Achieved title of Special Process Expert of “Torque Tightening” for Alstom India.
 JCB India Ltd. -
 Achieved 30% Productivity Rise in union agreement (LTS) for period 2012 to 2015.
 JCB India Award - To increase 20% capacity of powder coating plant by designing new hangers.
 Compactor Assembly Line capacity increase from 3 to 5 compactors/shift.
 Successfully productionised new wheeled loading showel models (WLS422ZX and WLS455ZX).
 Mahindra & Mahindra -
 Director Appreciation letter for labor cost saving of Rs 1.03 Crs. in 2012.
 Motion study and Line balancing for 4 new models (Bolero refresh, Thar, Quonto and Scorpio).
 Kirloskar Brothers Ltd. -
 Achieved 66.67% productivity rise in union agreement at Shirwal plant.
 UMAS Pvt. Ltd. -
 Bosch India Ltd. Jalgaon – Machine Shop’s MOP increased by 70% and Manpower Saving 75 Nos.
ORGANISATIONS ASSOCIATED WITH
Company Designation Department From To
Alstom Transport India Process Engineer Advance Indus 20-Jul-2015 Till Date
JCB India Ltd. Deputy Manager Manufacturing Engineering 20-Dec-2011 17-Jul-2015
Mahindra & Mahindra Assistant Manager Plant Engineering 03-Aug-2010 13-Dec-2011
Kirloskar Brothers Ltd. Assistant Manager Manufacturing Engineering 05-Feb-2009 07-Jul-2010
UMAS Pvt. Ltd. Consultant Projects 10-Jul-2007 31-Dec-2008
Software Skill
• Auto CAD ● Time Study software (MDAT, PDMS)
• MS Office Excel ● SAP (PP & MM Module)
• MS Project ● Knowledge of PLM, Catia-V5, Enoiva
ACADEMIC CREDENTIALS
Qualification University / Board Year of Passing Class
B.E. (Mechanical) Pune 2007 First Class
H.S.C. Pune 2003 First Class
S.S.C. Pune 2001 First Class
PERSONAL DETAILS
 Date of Birth : 12th May 1986
 Marital Status : Married
 Languages known : English, Hindi, Marathi
 Hobbies : Playing Cricket
 Pass port : G5477421
 Address : Flat No.C-302, Sr.No.-18/3, Lotus Grace, Kamal Park, Dhanori, Pune, 411015

3. Place :
Date : Bhushan S. Bhapkar