Rajesh B Wankhade has over 28 years of experience in production and maintenance operations. He has held roles such as Senior Manager overseeing painting, assembly, and fuel tank operations with a team of over 300 people. He is skilled in areas like strategic planning, process optimization, and project execution. In his career, he has introduced new models, minimized defects and costs, improved productivity through kaizen projects, and enhanced safety. He holds a B.E. in Mechanical Engineering and a diploma in Business Management.

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