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Profile:
A Graduate Ceramics Engineer with near to 12 Years of working experience in
different European & Indian MNCs Companies in the areas like R&D,
Business Excellence / WCM, Quality Control & Quality Assurance, Customer
Assurance, Advance & Modern Ceramics and Vitrified Process, Soft Ferrites
Manufacturing, Vitrified Bonded Abrasives, Optical Glass Preform and Optical
Fiber Manufacturing, Tunnel & Batch Kilns Operation & Production and Refractory
Maintenance etc.
Objective: Seeking assignments in Manufacturing Operation in Ceramics Industries where I could contribute
significantly to improvise the operational Excellency by implementing the world class practices out of hard core
experience, knowledge & expertise gathered while working in different functions in manufacturing operation in
different European and Indian MNCs.
PERSONAL DETAILS
Date of Birth: 8th
June, 1979
Gender: Male
Marital Status: Married
Permanent Address: 101/J, Lal Bahadur Sastry Road, P.O: Konnagar, Dist: Hooghly, West Bengal - 712235
Present Address: Flat no-3, 2nd
Floor, Rajesh Apartment, Umaji Colony, Bansilal nagar, Aurangabad,
Maharastra -431001
Notice Period: 2 months
Current CTC: INR 13.56 Lacs
Expected CTC: 40% hike (Negotiable)
Language Known: English, Hindi & Bengali etc
Passport Details: Z024054, valid up to: 23/11/2016
Contact Detail:
Mobile: +91-9561479922 (O); +91-8600008545 (H)
E-Mail: arup.barmanroy@gmail.com
BRIEF OVERVIEW:
From To
Jun.2004 Mar.2007
A - NAME OF COMPANY: EPCOS (Ferrites) India Pvt. Ltd. (EPCOS AG is a leading
manufacturer of electronic components and modules
headquartered in Munich)
PRODUCTS OF THE COMPANY Capacitors, Ferrites, Inductors, Resistors, Surface Acoustic
Wave Devices, Waveguide Components. Epcos is a leading
manufacturer of electronic components and modules
headquartered in Munich
REPORTING TO Development Head- Ferrite Division India
DESIGNATION Engineer -R&D – Material, Process & Product development
Apr.2007 Oct.2010
B - NAME OF COMPANY Saint-Gobain Abrasives
PRODUCTS OF THE COMPANY Vitrified Bonded Abrasives Grinding Wheels, Glass Bond Mix etc
REPORTING TO Adm. Reporting - Manufacturing Head Nagpur plant and Process
Head –Vitrified Operation
DESIGNATION Vitrified Bonded Abrasives Process, Kilns Operation &
Process, QC & QA Head - Nagpur
Nov.2010 Till date
C - NAME OF COMPANY Sterlite Technologies Ltd
PRODUCTS OF THE COMPANY Optical Glass Preform, Optical Fiber Natural – Single Mode
Fiber & Double Mode Optical Fiber, New generation and low
loss optical Fiber, Colored and Ring Mark Optical Fibers
REPORTING TO Adm. Reporting -Plant Manager Optical Fiber Plant Shendra,
Functional Reporting - Head Quality Assurance & Business
Excellence --India Operation
DESIGNATION Head Quality Assurance
Near to 12 Years of Experience in HOD level Role to handle functions independently
~ Align and abide by core values
~ Exhibit leadership qualities, result driven, self-awareness, improvement oriented and people oriented
capabilities
~ Experience in Enhancing Processes thru Quality Improvements initiatives to finally improving quality to
Reducing Manufacturing Costs
~ Extensive business background in multi-cultural environments
~ An enterprising leader with dexterity in directing cross cultural teams to design and deploy best practices
~ A result oriented professional with close to 12 years of rich experience in Business Excellence area, strategies,
culture development and customer concentric drive and focused approached to upgrade product brand image in-
terms of quality, cost, on-time delivery and after sales service.
~ Proven skills in contributing true results in customer satisfaction perspectives by delivering Quality products
and quality services with lost cost, intimating knowledge into within and outside the quality team of team about
VOC and to way forward to satisfy thru VOP,
~ Skilled at developing and executing high-level strategies as well as making high-stakes decisions and combating
mission-critical business challenges
~ A keen planner, strategist and implementer with deftness in devising and implementing strategies aimed at
ensuring successful running and managing quality function
~ Proficient in driving operations encompassing customer relationship management, administration, finalization
of strategic alliances,
~ An impressive analyser for identifying actual constraints in operation to achieve the targeted results with
honed CFT communication, motivation, team building, negotiation, presentation, convincing and analytical
skills. Ability to think out-of-the-box and contribute ideas towards achieving business excellence
~ Possess excellent leadership, analytical, planning, decision making and people management skills
Sterlite Technologies Ltd. is an Indian manufacturer of optical fibers, telecommunication cables and power
transmission conductors and exports optical fiber to overseas markets in China, Europe and South East Asia. It is
India's only fully integrated Optical Fiber producer and one of the largest suppliers of Optical Fibers to overseas
markets in China, Europe and South East Asia, America. Sterlite Technologies is partially owned by Sterlite
Industries (India) Limited, which is in turn 77%-owned by Vedanta Resources. The company has an optical fiber
manufacturing plant located at Aurangabad, India and China.
Working as Head Quality Control & Assurance, Customer Assurance and Management
Representative in Sterlite Technologies Ltd. A Vedanta Group of Companies,
Manufacturing of Optical Fibers for Telecommunication and Networking
Application: Duration – Nov-2010 to till date.
Manufacturing Products:
 Specially Chemical like Silicon Tetrachloride (SiCl4), Raw Materials – H2, O2, N2 etc for supporting Glass
Preform Manufacturing Plant
 Optical Glass Preform manufacturing and Dispatch for Fiber drawing operation
 Optical Fiber Manufacturing & dispatch for network and cable manufacturing
Current Roles & Responsibility:
 Leading the Unit Quality Assurance Head role for Sterlite Technologies Limited, Shendra – Aurangabad
facility.
 Responsible for driving of “Zero Customer complaint & Zero Defects” concepts within company.
 Responsible for handling customer complaints management system and to conduct Customer Complaint
Review Board within organization.
 Responsible for monitoring and analyse the customer satisfaction index and create the awareness and action
plan implementation throughout the organisation.
 Ensuring stringent adherence to quality standards, norms & practices, identifying gaps and taking corrective
& preventive measures.
 Co-ordating Lean Six Sigma Green and Yellow Belt Projects within OF-Sterlite Aurangabad facility to meet
the Business Plan.
 Handling plant Quality Management system and working as Management Representative for IMS - conducting
the periodic MRM with top management teams to address the chronic issues and address the action plans and
driving to close the gaps.
 Responsible to adhere and sustain the practices for ISO 9001: 2008 & TL9000 quality management
systems, ISO 14001, & ISO 18001 and Business Continuity Management system ISO 22301:2012 standards
within the end to end operation.
 Responsible to “Change Management Process” to maintain and monitoring change control system.
 Responsible for Process & Product Certification and compliance.
 Responsible for Material & Vendor development and Supplier Assurance program.
 Monitoring and measurement COPQ tools and driving the improvements and sustenance Programs.
 Responsible for the entire inbound and outbound of materials inspection required for Raw Material Plant,
Chemical Plant, Optical Glass Plant Fiber Manufacturing Plant.
CORE COMPETENCIES
Strategy Making
 Developing strategy to out of practical issues in shop and market demand to fulfil the customer requirements,
Product Quality, Capability & yield improvements, First Time Right and OEE improvements.
 Generating development plans & strategies out of customer feedbacks and to cater the market demand.
 Generating Business Plan by quality and production by keeping the present flaws in system and predictive
manufacturing requirements interms if customer and production.
 Creating and driving plans to improve the First Time Methodology
 Attention to detail Accomplishing tasks through concern for all areas involved, no matter how small; showing
concern for all aspects of the job; accurately checking progress and tasks; maintaining watchfulness over a
period of time
 Customer Service Orientation - Making efforts to listen to and understand the customer (both internal and
external); anticipating customer needs; giving high priority to Customer satisfaction.
 Communication Cluster - this includes the competencies of listening, oral & written communication.
 Planning & Organizing - Establishing a course of action for self or others to accomplish a specific goal;
planning proper assignments of personnel and appropriate allocation of resources.
 Teamwork - Active participation in, and facilitation of, team effectiveness; taking actions that demonstrate
consideration for the feelings and needs of others; being aware of the effect of one's behaviour on others.
 Analysis - Securing relevant information and identifying key issues and relationships from a base of
information; relating and comparing data from different sources; identifying Cause-effect relationships.
 FollowUp - Establishing procedures to monitor the results of delegations, assignments, or projects; taking into
consideration the skills, knowledge, and experience of the assigned individual and characteristics of the
assignment.
WCM & Business Excellence Initiates
 A self-motivated person with intuition and deep analytical skill to identifying the constraint of operational
issues and drive with elimination approach,
 Drive Kaizen, Poka-yoke and LSS approaches to eliminate and reduce scarp and improve quality of products
 Approaching with process based, data based and fact based analysis and drive to PDCA culture and approach
for enhancing process capability,
 Proficient with Quality Engineering and PFMEA based approaches to dive the TQM methodology
Quality Management System
 Resolving technical problems of vender, conducting rejection analysis for improving the vender quality and
providing feedback to vendor; reviewing quality assurance procedures, inspection manuals & inspection
report & vetting as per the standards.
 Formulating necessary execution plan to comply with applicable quality standards & terms of reference from
the clients; taking corrective & preventive actions on the non-conformance or rejection of the incoming
material.
 Ensuring the documentation and implementation of procedures and systems as per QMS at all stages of
process; analysing non-conformances and improving supplier quality to meet the organization’s
requirements.
 MRM, Internal & External Certification for ISO9001, 14000, 18000, TL9000, ISO 14001 & ISO 18001 audit
conduct and closure of findings.
 Weekly Quality Report publishing for overall communication on the Business Performance Indicator
 Quality Health Index monitoring on monthly basis to evaluate the performance level on the corporate level.
Quality Assurance & Testing
 Taking stringent quality measures including preparation / maintenance of necessary documents to ensure
compliance with above standards & customer requirements.
 Conducting vendor audits and monitoring day-to-day supplier performance to ensure that materials / spare
parts procured confirm to the industrial quality standards.
 Developing & evaluating vendor and conducting periodic audit of vendor and subcontract process.
Customer Assurance & Complaint handling System:
 Understanding customer needs and generating compliance against their requirement
 Plan and execute to meet the customer needs in effective and efficient way
 Ensure customer response on time as per standard practice for any feedback and complaint
 Standardise the process from RFQ to Order delivery with close knit observation and analysis to assure brand
image and zero business loss
 Handle customer feedback with utmost sense and data and fact based system approach. Conducting
Customer Complaint Review Board within CFT teams.
Quality Control, PDI & FG Assurance:
 Implementing Statistical Understanding customer needs and generating compliance against their
requirement
 Plan and execute to meet the customer needs in effective and efficient way
 Ensure customer response on time as per standard practice for any feedback and complaint
 Standardise the process from RFQ to Order delivery with close knit observation and analysis to assure brand
image and zero business loss
 Handle customer feedback with utmost sense and data and fact based system approach
Supplier Assurance & Material Assurance
 Plan & execute for the material and vendor or supplier development program with Supply Chain Management
team for financial year as per the business criticality.
 Plan & execute for the vendor visit audit program for the new and existing supplier as per the business call
and as a part of Supply Assurance Program to ensure and assure the quality, low cost, on-time, enhance
material with high post service assurance from the vendor.
 Plan and execute the Quality Material to be issued for the production to reduce the chance of least
variation/rejection for Raw Materials and Consumables.
 Enhance the standardization and testing methodology for testing of the incoming goods as per the testing
process at the vendor place and in the plant facility to reduce the variation in acceptance procedure at both
places.
 Conducting periodic and emergency Material Review Board Meeting for meeting and developing RM & Packing
materials requirements.
In-Process Quality
 Plan and execute to meet the In-Process Material Quality Objectives of plant
 Ensure the standardisation improvement in testing process, procedure and Quality plan to achieve plant
objectives to improve the process control mechanism
 Assure the employee training and education to change with the statistical Process Control mechanism and
variable quality Testing Plan process as per the Process quality
 Improve the testing instruments to reduce the time for inspection
 Critical control the ECR & ECN mechanism thru out the plant to put the strong control over permanent
change mechanism
 Strongly & critically monitor the Non-Confirm Material movement procedure to reduce the skip/leakage of
non-conform material at any moment
Kilns Operation and Production (Tunnel and Batch Kilns)
 Possess an in-depth understanding of Tunnel and Batch Kilns operation for firing or sintering of ceramics
products.
 Possess a good operational knowledge to improve the Kilns capacity and daily monitoring of kilns condition.
 Understand the knowhow of kiln process flow to upgrade it next level to achieve the design efficiency in
terms of thru put & fuel efficiency.
Team Management
 Leading, mentoring & monitoring the performance of team members to ensure efficiency in process
operations in order to maintain quality policy and achieve quality objectives of the company.
 Creating & sustaining dynamic environment that fosters development opportunities and motivates high
performance amongst team members. Training operators on product, process and quality management
system.
Achievements:
 Last 1 year there is no customer complaint received against any delivery.
 Promoting “ZERO DEFECTS” concept within organization by adopting DMAIC methodology for eliminating
defects from system,
 Conducted 2 batches of Lean Six Sigma Green Belt Certification program thru out the OF organization and
more than 25 projects have been completed as of now.
 Reduced customer complaint/Mn Fkm fiber by 37% in FY 14-15 w.r.t FY 13-14. (in FY 13-14 Customer
complaint/ Mn-Fkm Fiber Dispatch – 9.57 & in FY 14-15 achieved 6.02).
 External failure reduction from 15.2 lacs to 0.46 Lacs from FY 13-14 to FY 14-15.
 Average time to close customer complaint, reduced from 15 days to 9 days in FY14-15.
 Customer satisfaction index for key accounts increased from 85% in first half of FY15-16.
 Monitoring the First Time Right Approach throughout the manufacturing performance – Achieved 20%
improvement within last 7 months.
 Monitoring the Monthly Quality Health Index Performance to achieve the corporate quality goal – improve
15% within last 7 month.
 Completed Implementation cycles for TL9000 and ISO10002 standards for Shendra plant.
 Completed 25 of successful customer audits in Shendra Plants without any major NCs in last 7 months in FY
15-16.
 Completed the surveillance audit for IMS & TL 9001 and ISO 23301:2012 with no major NCs in Shendra Facility
current FY 15-16 year.
 Completed 2 RM –Vendor development within 2 years span for critical process inputs stabilization
 Completed 3 packing vendors developments and 30 Vendor qualification audit with last 4 Years
About SAINT-GOBAIN Abrasives:
Saint-Gobain Abrasives, a sector of Compagnie de Saint-Gobain, is a multinational corporation headquartered in Paris, France. Saint-
Gobain Abrasives is by far the w orld's number-one bonded abrasives manufacturer.
Bonded abrasives are natural or synthetic abrasive grains "bonded" into a solid form, usually in the shape of a w heel. Bonded abrasives
products also include grinding and cut-off w heels, snagging w heels, segments, mounted w heels, plugs, and cones.
Saint-Gobain produces more than 250,000 types of grinding w heels - w ith diameters ranging from just a few millimeters to nearly 2
meters (almost 6.5 feet) - designed to meet specific needs of our customers. Vitrified - or synthetic - w heels are made of clay-based
binder for precision grinding, sharpening, forming and finishing applications in the automotive, aerospace, and machine tool sectors.
Organic - or natural - w heels are made w ith rubber, shellac or plastic bonds for cutting and forming applications in markets such as
primary metals, w elding, and metal fabrication. Organic w heels can also be used to obtain very precise dimensions in rolling mill
cylinders and machining hypodermic needles.
Manufacturing Products:
Vitrified Bonded Abrasives Grinding Wheels, Glass Bond Mix etc
Roles & Responsibilities:
 Acting as WCM pillar for TQM, Continual Improvement Initiatives and Autonomous & Predictive Maintenance
for the bonded Abrasives business in Nagpur, plant.
 Responsible to implement Kaizens, Poka-Yoke, KANBAN and WCM improvement related initiatives in bonded
Nagpur business as per Business plan.
 Responsible for In-process Quality, Quality Control & Quality Assurance function of Nagpur Bonded abrasive
unit.
 Responsible for Vitrified Process and Kilns (Tunnel & Batch) operation & Production & Refractory and
predictive maintenance.
 Responsible for periodic measuring, monitoring and maintaining of Kilns Health, safety and Risk evaluation,
generation action and closure of gaps for Tunnels and Batch Kilns
 Responsible for Refractory maintenance of Tunnel and Batch Kilns as on when required
 Responsible for Kilns – performance, measurement, monitoring and refractory maintenance
 Conversant with Kilns Shut down and start up activities
 Responsible for driving scrap / rejection reduction program thru Lean Six Sigma Program & improvement
initiatives for input / output ratio for raw materials.
 Responsible to provide resolution of Customer complaints & implementing CA&PA at manufacturing sites
 Planning Kilns production with monthly production plan & execution throughout the month to achieve the
on-time; achieving the Fuel Efficiency, Operational efficiency, hourly production at Kilns at Kilns.
 Carrying predictive maintenance in Kilns to avoid unwanted major breakdown or Loss time.
 Maintaining the emergency stock of critical kilns spare parts at department level to get rid of from
emergency breakdown.
 Responsible to develop new supplier for Kiln Furniture and refractory maintenance
 Ensuring compliance of statutory regulations at Kilns.
Projects Accomplished:
Worked as Sr. Engineer – Ceramic Vitrified Process, Kilns Process & Production, QC &
QA – in Saint- Gobain Abrasives Ltd., Mumbai & Nagpur Manufacturing plants:
Duration April 2007 - Oct 2010
 Improving Sp. Fuel consumption in kilns from 0.34 Ltrs/Kg to 0.29 Ltrs/Kg.
 Reducing of variable cost of Kilns from 85 Lacks/Annum to 70 Lacks/Annum @ 375 tons/month.
 Carrying out every EMPs & OMPs related projects for Kilns area.
 Leading one DMAIC Project of Reduction of Stones Fired rejection from 4.75% to 2.4%.
 Working as a Team member for DMAIC project of green waste reduction in mixing & moulding area from 6.5%
to 3%.
 Responsible to reduce the breakdown time in Tunnel Kiln from 0.19% to >0.09% within first six month &
>0.06% within last six month. For Batch Kilns from B/D reduction from 0.28% to 15% in YTD 2010.
Achievements:
 Reduced Customer complaint 25% within 3.5 Yrs.
 Completed 3 nos DMAIC Green belt project in 2007-2009 DMAIC projects.
 Achieved Rejection% reduction from 11.5% to 7.5% within first 6 month
 Established & introduced two SPC techniques for Mixing & Moulding Quality measurement and monitoring to
sustain with desired results
 Introduced moulding control chart density related rejection.
 Introduced a new cost effective binder system for Vitrified abrasives to improve the overall green strength of
the raw moulding products.
 Reduced air & oven drying time by 7 hrs to reduce the manufacturing lead time & improvement of
productivity.
 Introduced less weight refractory spacers and less thicker refractory batts to increase the loading capacity
by 18% by 2.5 yrs
 Reduced Refractory consumption by reducing handling system and thermal shock in ware cooling zone
Company Profile: A German MNC based company located at Kalyani, Nadia, West Bendgal. TDK Corporation is a
leading electronic components company and markets the product brands TDK and EPCOS. The portfolio of TDK's passive components
About EPCOS-TDK-AG
TDK Corporation is a leading electronic components company and markets the product brands TDK and EPCOS. The portfolio of TDK's
passive components business includes ceramic, aluminum electrolytic and film capacitors, ferrites and inductors, magnets, high-
frequency components such as surface acoustic w ave (SAW) filter products and modules, piezo and protection components and
sensors. TDK focuses on demanding markets in the areas of information and communication technology and consumer, automotive
and industrial electronics
Manufacturing Products:
Ferrites and inductors, magnets, high-frequency components such as surface acoustic wave (SAW) filter products
and modules
Roles & Responsibilities:
 Worked as Research & development Engineer for manufacturing of MnZn ferrite product in EPCOS
Ferrites Limited
 Responsible to design new and cost effective raw materials for the Ferrite Division of EPCOS India
 Handling & Control on Brands Batch Kiln Operation of for R&D.
 Responsible to improve loading profiles at Kilns to reduce handling rejection.
 Measuring the surface area of the coarser and finer milling slurry and making the pallets for XRF
measurement.
 Measuring various electrical measurements for critical and important cores.
 To introduce new raw materials in the production line.
Worked as Research & Development Engineer – Process, Material & Product
Development in EPCOS India Pvt. Ltd. Kalyani-West Bengal
Duration: Jul- 2004 – Mar 2007
 Development of manufacturing process to meet customer requirements and product quality.
 Development of new materials out of market demand.
 Technology transfer from semi-plant to the successive production line.
 Responsible for Technical approval of external ferrite material for Ferrite Division of EPCOS.
 Responsible for Transfer of Equipment’s for local R&D centre in Kalyani,
 Key member for set up the R&D Lab at kalyani, West Bengal
 Trained to run & operate Semi-plant for wet mixing process
 Conversant with operation – Riedhammer Tunnel & Brands Batch Kilns
 Conversant for releasing material, testing conductivity, pH, BD, BET, flow ability etc.
 Conversant with other advanced Physical, Chemical measurement of material like XRF DSC, BET method and
Ceramic Slurry parameters.
 Conversant with Power Metallurgy Process and Preparation of Materials, Spray Drying, Molding, Drying &
Sintering process
 Sample preparation, measurement & validation for final customer approval
 Providing technical suggestion for using materials and process technology for new Ferrite products.
 Participate in cross functionality team activity like Six-Sigma, Sample Development Review,
 Technology Transfer and pilot launch of products in Mass production.
 The work included Vendor Development. Conducting Fabrication trial and testing the finished parts
for technical approval of new material.
 Worked as responsible for solving technical process problem of EPCOS Ferrites Ltd
 Conversant with XRF - X-ray Spectroscopy (SRS 3000) for chemical analysis
Achievements:
 High level of contribution in developing the below materials in EPCOS during 2 yrs and 9 months tenure:
 T36 material in Magnetic component
 N51 material for EPCOS in component
 N95 presented in Electronika
 Work as key team member for developed and commercially Introduce 3 new Ferrite Materials – N95, T36 and
N51 during 2005-2007 in Local R&D centre at Kalyani.
 Introduced 5 cost effective raw materials to reduce the overall FG cost in 2004-2006 time period.
 Reduce the rejection level from 25% to 15% for N49 material in 2004.
 Introduce new sintering cycle to improve the Spinel structure for high permeable and low power loss
material in 2005.
 Successfully completed technology transfer from semi-plant to the successive production line.
PROFESSIONAL QUALIFICATION:
Sr.
No.
Examination
Board /
University / college.
Year of
passing
% Marks
1
B.Tech
(Ceramics)
Govt. College of Engineering & ceramic
Technologies (formerly known as College
of Ceramic Technologies; Beliaghata,
Kolkata)/ Calcutta University
2004
69%
(Distinction)
2 10+2 Standard
Konnagar High School; Konnagar, Hooghly,
West Bengal
1998
64.3%
(Distinction)
3 10th
Standard K R S V, Konnagar, Hooghly, West Bengal 1996
70%
(Distinction)
 Certified Lead Auditor in ISO 9001: from DNV Business Assurance, Certificate License no – 28364,Certified by
IRCA.
 Certified Green belt in DMAIC LSS from Sterlite Technologies Ltd. Internal certification agency
 Certified Internal Auditor for IMS system & Implementing knowledge
 Certified Internal Auditor from DNV Business Assurance and also have implemented this standards in 2 plants in
Aurangabad
Other Expertise & Skill:
 Certified IMS Internal Auditor
 Certified BCMS Internal Auditor
 MSA and SPC Trained
 I have completed ISO 9001:2008 Lead Auditor Certification course from DNV in Nov-2012.
 Certified Internal auditor for BCMS- ISO 22301:2012
 Competent Process and Systemauditor for in-process and vendorprocess
 I have attended 3 days OBT Training program in 2010 at Garudnmachi from High Places.
 I have attended Lean Six Sigma Green Belt Training Program from Qual Mind Global- Bangalaore.
 I have attended Lean Six Sigma Green Belt Training Program from Qultima –Pune.
 Attended SupervisorExcellency Program in 2012
 Attended 1 Minute Manager Course
 Converse with PPAP, APAP, FMEA, C&E, COPQ, DWM etc
Hobbies:
 Reading Books
 Listening Music
 Solving Puzzles
 Watching Thriller movies
Strengths:
 Honest,Hardworking,
 Strong orientation with customer needs / expectation
 Can handle & communicate well with customer, vendor& internal team
 Well regarded for interpersonal, written and oral communication skill.
 Can handle multiple tasks simultaneously.
 Ability to acquire and apply knowledge rapidly.
 Can work independently with minimal supervision and contributes to a team
Computer Skills:
 Operating System: Windows
 SAP Applications
 Oracle Applications
Thank you, for going through my resume.
Place: Aurangabad – Maharastra
Date: 20/12/2015 Arup Barman Roy

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Resume Arup Barman Roy

  • 1. Resume Profile: A Graduate Ceramics Engineer with near to 12 Years of working experience in different European & Indian MNCs Companies in the areas like R&D, Business Excellence / WCM, Quality Control & Quality Assurance, Customer Assurance, Advance & Modern Ceramics and Vitrified Process, Soft Ferrites Manufacturing, Vitrified Bonded Abrasives, Optical Glass Preform and Optical Fiber Manufacturing, Tunnel & Batch Kilns Operation & Production and Refractory Maintenance etc. Objective: Seeking assignments in Manufacturing Operation in Ceramics Industries where I could contribute significantly to improvise the operational Excellency by implementing the world class practices out of hard core experience, knowledge & expertise gathered while working in different functions in manufacturing operation in different European and Indian MNCs. PERSONAL DETAILS Date of Birth: 8th June, 1979 Gender: Male Marital Status: Married Permanent Address: 101/J, Lal Bahadur Sastry Road, P.O: Konnagar, Dist: Hooghly, West Bengal - 712235 Present Address: Flat no-3, 2nd Floor, Rajesh Apartment, Umaji Colony, Bansilal nagar, Aurangabad, Maharastra -431001 Notice Period: 2 months Current CTC: INR 13.56 Lacs Expected CTC: 40% hike (Negotiable) Language Known: English, Hindi & Bengali etc Passport Details: Z024054, valid up to: 23/11/2016 Contact Detail: Mobile: +91-9561479922 (O); +91-8600008545 (H) E-Mail: arup.barmanroy@gmail.com BRIEF OVERVIEW: From To Jun.2004 Mar.2007 A - NAME OF COMPANY: EPCOS (Ferrites) India Pvt. Ltd. (EPCOS AG is a leading manufacturer of electronic components and modules headquartered in Munich) PRODUCTS OF THE COMPANY Capacitors, Ferrites, Inductors, Resistors, Surface Acoustic Wave Devices, Waveguide Components. Epcos is a leading manufacturer of electronic components and modules headquartered in Munich REPORTING TO Development Head- Ferrite Division India DESIGNATION Engineer -R&D – Material, Process & Product development Apr.2007 Oct.2010 B - NAME OF COMPANY Saint-Gobain Abrasives PRODUCTS OF THE COMPANY Vitrified Bonded Abrasives Grinding Wheels, Glass Bond Mix etc REPORTING TO Adm. Reporting - Manufacturing Head Nagpur plant and Process Head –Vitrified Operation
  • 2. DESIGNATION Vitrified Bonded Abrasives Process, Kilns Operation & Process, QC & QA Head - Nagpur Nov.2010 Till date C - NAME OF COMPANY Sterlite Technologies Ltd PRODUCTS OF THE COMPANY Optical Glass Preform, Optical Fiber Natural – Single Mode Fiber & Double Mode Optical Fiber, New generation and low loss optical Fiber, Colored and Ring Mark Optical Fibers REPORTING TO Adm. Reporting -Plant Manager Optical Fiber Plant Shendra, Functional Reporting - Head Quality Assurance & Business Excellence --India Operation DESIGNATION Head Quality Assurance Near to 12 Years of Experience in HOD level Role to handle functions independently ~ Align and abide by core values ~ Exhibit leadership qualities, result driven, self-awareness, improvement oriented and people oriented capabilities ~ Experience in Enhancing Processes thru Quality Improvements initiatives to finally improving quality to Reducing Manufacturing Costs ~ Extensive business background in multi-cultural environments ~ An enterprising leader with dexterity in directing cross cultural teams to design and deploy best practices ~ A result oriented professional with close to 12 years of rich experience in Business Excellence area, strategies, culture development and customer concentric drive and focused approached to upgrade product brand image in- terms of quality, cost, on-time delivery and after sales service. ~ Proven skills in contributing true results in customer satisfaction perspectives by delivering Quality products and quality services with lost cost, intimating knowledge into within and outside the quality team of team about VOC and to way forward to satisfy thru VOP, ~ Skilled at developing and executing high-level strategies as well as making high-stakes decisions and combating mission-critical business challenges ~ A keen planner, strategist and implementer with deftness in devising and implementing strategies aimed at ensuring successful running and managing quality function ~ Proficient in driving operations encompassing customer relationship management, administration, finalization of strategic alliances, ~ An impressive analyser for identifying actual constraints in operation to achieve the targeted results with honed CFT communication, motivation, team building, negotiation, presentation, convincing and analytical skills. Ability to think out-of-the-box and contribute ideas towards achieving business excellence ~ Possess excellent leadership, analytical, planning, decision making and people management skills Sterlite Technologies Ltd. is an Indian manufacturer of optical fibers, telecommunication cables and power transmission conductors and exports optical fiber to overseas markets in China, Europe and South East Asia. It is India's only fully integrated Optical Fiber producer and one of the largest suppliers of Optical Fibers to overseas markets in China, Europe and South East Asia, America. Sterlite Technologies is partially owned by Sterlite Industries (India) Limited, which is in turn 77%-owned by Vedanta Resources. The company has an optical fiber manufacturing plant located at Aurangabad, India and China. Working as Head Quality Control & Assurance, Customer Assurance and Management Representative in Sterlite Technologies Ltd. A Vedanta Group of Companies, Manufacturing of Optical Fibers for Telecommunication and Networking Application: Duration – Nov-2010 to till date.
  • 3. Manufacturing Products:  Specially Chemical like Silicon Tetrachloride (SiCl4), Raw Materials – H2, O2, N2 etc for supporting Glass Preform Manufacturing Plant  Optical Glass Preform manufacturing and Dispatch for Fiber drawing operation  Optical Fiber Manufacturing & dispatch for network and cable manufacturing Current Roles & Responsibility:  Leading the Unit Quality Assurance Head role for Sterlite Technologies Limited, Shendra – Aurangabad facility.  Responsible for driving of “Zero Customer complaint & Zero Defects” concepts within company.  Responsible for handling customer complaints management system and to conduct Customer Complaint Review Board within organization.  Responsible for monitoring and analyse the customer satisfaction index and create the awareness and action plan implementation throughout the organisation.  Ensuring stringent adherence to quality standards, norms & practices, identifying gaps and taking corrective & preventive measures.  Co-ordating Lean Six Sigma Green and Yellow Belt Projects within OF-Sterlite Aurangabad facility to meet the Business Plan.  Handling plant Quality Management system and working as Management Representative for IMS - conducting the periodic MRM with top management teams to address the chronic issues and address the action plans and driving to close the gaps.  Responsible to adhere and sustain the practices for ISO 9001: 2008 & TL9000 quality management systems, ISO 14001, & ISO 18001 and Business Continuity Management system ISO 22301:2012 standards within the end to end operation.  Responsible to “Change Management Process” to maintain and monitoring change control system.  Responsible for Process & Product Certification and compliance.  Responsible for Material & Vendor development and Supplier Assurance program.  Monitoring and measurement COPQ tools and driving the improvements and sustenance Programs.  Responsible for the entire inbound and outbound of materials inspection required for Raw Material Plant, Chemical Plant, Optical Glass Plant Fiber Manufacturing Plant. CORE COMPETENCIES Strategy Making  Developing strategy to out of practical issues in shop and market demand to fulfil the customer requirements, Product Quality, Capability & yield improvements, First Time Right and OEE improvements.  Generating development plans & strategies out of customer feedbacks and to cater the market demand.  Generating Business Plan by quality and production by keeping the present flaws in system and predictive manufacturing requirements interms if customer and production.  Creating and driving plans to improve the First Time Methodology  Attention to detail Accomplishing tasks through concern for all areas involved, no matter how small; showing concern for all aspects of the job; accurately checking progress and tasks; maintaining watchfulness over a period of time  Customer Service Orientation - Making efforts to listen to and understand the customer (both internal and external); anticipating customer needs; giving high priority to Customer satisfaction.  Communication Cluster - this includes the competencies of listening, oral & written communication.  Planning & Organizing - Establishing a course of action for self or others to accomplish a specific goal; planning proper assignments of personnel and appropriate allocation of resources.  Teamwork - Active participation in, and facilitation of, team effectiveness; taking actions that demonstrate consideration for the feelings and needs of others; being aware of the effect of one's behaviour on others.  Analysis - Securing relevant information and identifying key issues and relationships from a base of information; relating and comparing data from different sources; identifying Cause-effect relationships.
  • 4.  FollowUp - Establishing procedures to monitor the results of delegations, assignments, or projects; taking into consideration the skills, knowledge, and experience of the assigned individual and characteristics of the assignment. WCM & Business Excellence Initiates  A self-motivated person with intuition and deep analytical skill to identifying the constraint of operational issues and drive with elimination approach,  Drive Kaizen, Poka-yoke and LSS approaches to eliminate and reduce scarp and improve quality of products  Approaching with process based, data based and fact based analysis and drive to PDCA culture and approach for enhancing process capability,  Proficient with Quality Engineering and PFMEA based approaches to dive the TQM methodology Quality Management System  Resolving technical problems of vender, conducting rejection analysis for improving the vender quality and providing feedback to vendor; reviewing quality assurance procedures, inspection manuals & inspection report & vetting as per the standards.  Formulating necessary execution plan to comply with applicable quality standards & terms of reference from the clients; taking corrective & preventive actions on the non-conformance or rejection of the incoming material.  Ensuring the documentation and implementation of procedures and systems as per QMS at all stages of process; analysing non-conformances and improving supplier quality to meet the organization’s requirements.  MRM, Internal & External Certification for ISO9001, 14000, 18000, TL9000, ISO 14001 & ISO 18001 audit conduct and closure of findings.  Weekly Quality Report publishing for overall communication on the Business Performance Indicator  Quality Health Index monitoring on monthly basis to evaluate the performance level on the corporate level. Quality Assurance & Testing  Taking stringent quality measures including preparation / maintenance of necessary documents to ensure compliance with above standards & customer requirements.  Conducting vendor audits and monitoring day-to-day supplier performance to ensure that materials / spare parts procured confirm to the industrial quality standards.  Developing & evaluating vendor and conducting periodic audit of vendor and subcontract process. Customer Assurance & Complaint handling System:  Understanding customer needs and generating compliance against their requirement  Plan and execute to meet the customer needs in effective and efficient way  Ensure customer response on time as per standard practice for any feedback and complaint  Standardise the process from RFQ to Order delivery with close knit observation and analysis to assure brand image and zero business loss  Handle customer feedback with utmost sense and data and fact based system approach. Conducting Customer Complaint Review Board within CFT teams. Quality Control, PDI & FG Assurance:  Implementing Statistical Understanding customer needs and generating compliance against their requirement  Plan and execute to meet the customer needs in effective and efficient way  Ensure customer response on time as per standard practice for any feedback and complaint  Standardise the process from RFQ to Order delivery with close knit observation and analysis to assure brand image and zero business loss  Handle customer feedback with utmost sense and data and fact based system approach Supplier Assurance & Material Assurance  Plan & execute for the material and vendor or supplier development program with Supply Chain Management team for financial year as per the business criticality.
  • 5.  Plan & execute for the vendor visit audit program for the new and existing supplier as per the business call and as a part of Supply Assurance Program to ensure and assure the quality, low cost, on-time, enhance material with high post service assurance from the vendor.  Plan and execute the Quality Material to be issued for the production to reduce the chance of least variation/rejection for Raw Materials and Consumables.  Enhance the standardization and testing methodology for testing of the incoming goods as per the testing process at the vendor place and in the plant facility to reduce the variation in acceptance procedure at both places.  Conducting periodic and emergency Material Review Board Meeting for meeting and developing RM & Packing materials requirements. In-Process Quality  Plan and execute to meet the In-Process Material Quality Objectives of plant  Ensure the standardisation improvement in testing process, procedure and Quality plan to achieve plant objectives to improve the process control mechanism  Assure the employee training and education to change with the statistical Process Control mechanism and variable quality Testing Plan process as per the Process quality  Improve the testing instruments to reduce the time for inspection  Critical control the ECR & ECN mechanism thru out the plant to put the strong control over permanent change mechanism  Strongly & critically monitor the Non-Confirm Material movement procedure to reduce the skip/leakage of non-conform material at any moment Kilns Operation and Production (Tunnel and Batch Kilns)  Possess an in-depth understanding of Tunnel and Batch Kilns operation for firing or sintering of ceramics products.  Possess a good operational knowledge to improve the Kilns capacity and daily monitoring of kilns condition.  Understand the knowhow of kiln process flow to upgrade it next level to achieve the design efficiency in terms of thru put & fuel efficiency. Team Management  Leading, mentoring & monitoring the performance of team members to ensure efficiency in process operations in order to maintain quality policy and achieve quality objectives of the company.  Creating & sustaining dynamic environment that fosters development opportunities and motivates high performance amongst team members. Training operators on product, process and quality management system. Achievements:  Last 1 year there is no customer complaint received against any delivery.  Promoting “ZERO DEFECTS” concept within organization by adopting DMAIC methodology for eliminating defects from system,  Conducted 2 batches of Lean Six Sigma Green Belt Certification program thru out the OF organization and more than 25 projects have been completed as of now.  Reduced customer complaint/Mn Fkm fiber by 37% in FY 14-15 w.r.t FY 13-14. (in FY 13-14 Customer complaint/ Mn-Fkm Fiber Dispatch – 9.57 & in FY 14-15 achieved 6.02).  External failure reduction from 15.2 lacs to 0.46 Lacs from FY 13-14 to FY 14-15.  Average time to close customer complaint, reduced from 15 days to 9 days in FY14-15.  Customer satisfaction index for key accounts increased from 85% in first half of FY15-16.  Monitoring the First Time Right Approach throughout the manufacturing performance – Achieved 20% improvement within last 7 months.  Monitoring the Monthly Quality Health Index Performance to achieve the corporate quality goal – improve 15% within last 7 month.  Completed Implementation cycles for TL9000 and ISO10002 standards for Shendra plant.  Completed 25 of successful customer audits in Shendra Plants without any major NCs in last 7 months in FY 15-16.  Completed the surveillance audit for IMS & TL 9001 and ISO 23301:2012 with no major NCs in Shendra Facility current FY 15-16 year.  Completed 2 RM –Vendor development within 2 years span for critical process inputs stabilization
  • 6.  Completed 3 packing vendors developments and 30 Vendor qualification audit with last 4 Years About SAINT-GOBAIN Abrasives: Saint-Gobain Abrasives, a sector of Compagnie de Saint-Gobain, is a multinational corporation headquartered in Paris, France. Saint- Gobain Abrasives is by far the w orld's number-one bonded abrasives manufacturer. Bonded abrasives are natural or synthetic abrasive grains "bonded" into a solid form, usually in the shape of a w heel. Bonded abrasives products also include grinding and cut-off w heels, snagging w heels, segments, mounted w heels, plugs, and cones. Saint-Gobain produces more than 250,000 types of grinding w heels - w ith diameters ranging from just a few millimeters to nearly 2 meters (almost 6.5 feet) - designed to meet specific needs of our customers. Vitrified - or synthetic - w heels are made of clay-based binder for precision grinding, sharpening, forming and finishing applications in the automotive, aerospace, and machine tool sectors. Organic - or natural - w heels are made w ith rubber, shellac or plastic bonds for cutting and forming applications in markets such as primary metals, w elding, and metal fabrication. Organic w heels can also be used to obtain very precise dimensions in rolling mill cylinders and machining hypodermic needles. Manufacturing Products: Vitrified Bonded Abrasives Grinding Wheels, Glass Bond Mix etc Roles & Responsibilities:  Acting as WCM pillar for TQM, Continual Improvement Initiatives and Autonomous & Predictive Maintenance for the bonded Abrasives business in Nagpur, plant.  Responsible to implement Kaizens, Poka-Yoke, KANBAN and WCM improvement related initiatives in bonded Nagpur business as per Business plan.  Responsible for In-process Quality, Quality Control & Quality Assurance function of Nagpur Bonded abrasive unit.  Responsible for Vitrified Process and Kilns (Tunnel & Batch) operation & Production & Refractory and predictive maintenance.  Responsible for periodic measuring, monitoring and maintaining of Kilns Health, safety and Risk evaluation, generation action and closure of gaps for Tunnels and Batch Kilns  Responsible for Refractory maintenance of Tunnel and Batch Kilns as on when required  Responsible for Kilns – performance, measurement, monitoring and refractory maintenance  Conversant with Kilns Shut down and start up activities  Responsible for driving scrap / rejection reduction program thru Lean Six Sigma Program & improvement initiatives for input / output ratio for raw materials.  Responsible to provide resolution of Customer complaints & implementing CA&PA at manufacturing sites  Planning Kilns production with monthly production plan & execution throughout the month to achieve the on-time; achieving the Fuel Efficiency, Operational efficiency, hourly production at Kilns at Kilns.  Carrying predictive maintenance in Kilns to avoid unwanted major breakdown or Loss time.  Maintaining the emergency stock of critical kilns spare parts at department level to get rid of from emergency breakdown.  Responsible to develop new supplier for Kiln Furniture and refractory maintenance  Ensuring compliance of statutory regulations at Kilns. Projects Accomplished: Worked as Sr. Engineer – Ceramic Vitrified Process, Kilns Process & Production, QC & QA – in Saint- Gobain Abrasives Ltd., Mumbai & Nagpur Manufacturing plants: Duration April 2007 - Oct 2010
  • 7.  Improving Sp. Fuel consumption in kilns from 0.34 Ltrs/Kg to 0.29 Ltrs/Kg.  Reducing of variable cost of Kilns from 85 Lacks/Annum to 70 Lacks/Annum @ 375 tons/month.  Carrying out every EMPs & OMPs related projects for Kilns area.  Leading one DMAIC Project of Reduction of Stones Fired rejection from 4.75% to 2.4%.  Working as a Team member for DMAIC project of green waste reduction in mixing & moulding area from 6.5% to 3%.  Responsible to reduce the breakdown time in Tunnel Kiln from 0.19% to >0.09% within first six month & >0.06% within last six month. For Batch Kilns from B/D reduction from 0.28% to 15% in YTD 2010. Achievements:  Reduced Customer complaint 25% within 3.5 Yrs.  Completed 3 nos DMAIC Green belt project in 2007-2009 DMAIC projects.  Achieved Rejection% reduction from 11.5% to 7.5% within first 6 month  Established & introduced two SPC techniques for Mixing & Moulding Quality measurement and monitoring to sustain with desired results  Introduced moulding control chart density related rejection.  Introduced a new cost effective binder system for Vitrified abrasives to improve the overall green strength of the raw moulding products.  Reduced air & oven drying time by 7 hrs to reduce the manufacturing lead time & improvement of productivity.  Introduced less weight refractory spacers and less thicker refractory batts to increase the loading capacity by 18% by 2.5 yrs  Reduced Refractory consumption by reducing handling system and thermal shock in ware cooling zone Company Profile: A German MNC based company located at Kalyani, Nadia, West Bendgal. TDK Corporation is a leading electronic components company and markets the product brands TDK and EPCOS. The portfolio of TDK's passive components About EPCOS-TDK-AG TDK Corporation is a leading electronic components company and markets the product brands TDK and EPCOS. The portfolio of TDK's passive components business includes ceramic, aluminum electrolytic and film capacitors, ferrites and inductors, magnets, high- frequency components such as surface acoustic w ave (SAW) filter products and modules, piezo and protection components and sensors. TDK focuses on demanding markets in the areas of information and communication technology and consumer, automotive and industrial electronics Manufacturing Products: Ferrites and inductors, magnets, high-frequency components such as surface acoustic wave (SAW) filter products and modules Roles & Responsibilities:  Worked as Research & development Engineer for manufacturing of MnZn ferrite product in EPCOS Ferrites Limited  Responsible to design new and cost effective raw materials for the Ferrite Division of EPCOS India  Handling & Control on Brands Batch Kiln Operation of for R&D.  Responsible to improve loading profiles at Kilns to reduce handling rejection.  Measuring the surface area of the coarser and finer milling slurry and making the pallets for XRF measurement.  Measuring various electrical measurements for critical and important cores.  To introduce new raw materials in the production line. Worked as Research & Development Engineer – Process, Material & Product Development in EPCOS India Pvt. Ltd. Kalyani-West Bengal Duration: Jul- 2004 – Mar 2007
  • 8.  Development of manufacturing process to meet customer requirements and product quality.  Development of new materials out of market demand.  Technology transfer from semi-plant to the successive production line.  Responsible for Technical approval of external ferrite material for Ferrite Division of EPCOS.  Responsible for Transfer of Equipment’s for local R&D centre in Kalyani,  Key member for set up the R&D Lab at kalyani, West Bengal  Trained to run & operate Semi-plant for wet mixing process  Conversant with operation – Riedhammer Tunnel & Brands Batch Kilns  Conversant for releasing material, testing conductivity, pH, BD, BET, flow ability etc.  Conversant with other advanced Physical, Chemical measurement of material like XRF DSC, BET method and Ceramic Slurry parameters.  Conversant with Power Metallurgy Process and Preparation of Materials, Spray Drying, Molding, Drying & Sintering process  Sample preparation, measurement & validation for final customer approval  Providing technical suggestion for using materials and process technology for new Ferrite products.  Participate in cross functionality team activity like Six-Sigma, Sample Development Review,  Technology Transfer and pilot launch of products in Mass production.  The work included Vendor Development. Conducting Fabrication trial and testing the finished parts for technical approval of new material.  Worked as responsible for solving technical process problem of EPCOS Ferrites Ltd  Conversant with XRF - X-ray Spectroscopy (SRS 3000) for chemical analysis Achievements:  High level of contribution in developing the below materials in EPCOS during 2 yrs and 9 months tenure:  T36 material in Magnetic component  N51 material for EPCOS in component  N95 presented in Electronika  Work as key team member for developed and commercially Introduce 3 new Ferrite Materials – N95, T36 and N51 during 2005-2007 in Local R&D centre at Kalyani.  Introduced 5 cost effective raw materials to reduce the overall FG cost in 2004-2006 time period.  Reduce the rejection level from 25% to 15% for N49 material in 2004.  Introduce new sintering cycle to improve the Spinel structure for high permeable and low power loss material in 2005.  Successfully completed technology transfer from semi-plant to the successive production line. PROFESSIONAL QUALIFICATION: Sr. No. Examination Board / University / college. Year of passing % Marks 1 B.Tech (Ceramics) Govt. College of Engineering & ceramic Technologies (formerly known as College of Ceramic Technologies; Beliaghata, Kolkata)/ Calcutta University 2004 69% (Distinction) 2 10+2 Standard Konnagar High School; Konnagar, Hooghly, West Bengal 1998 64.3% (Distinction)
  • 9. 3 10th Standard K R S V, Konnagar, Hooghly, West Bengal 1996 70% (Distinction)  Certified Lead Auditor in ISO 9001: from DNV Business Assurance, Certificate License no – 28364,Certified by IRCA.  Certified Green belt in DMAIC LSS from Sterlite Technologies Ltd. Internal certification agency  Certified Internal Auditor for IMS system & Implementing knowledge  Certified Internal Auditor from DNV Business Assurance and also have implemented this standards in 2 plants in Aurangabad Other Expertise & Skill:  Certified IMS Internal Auditor  Certified BCMS Internal Auditor  MSA and SPC Trained  I have completed ISO 9001:2008 Lead Auditor Certification course from DNV in Nov-2012.  Certified Internal auditor for BCMS- ISO 22301:2012  Competent Process and Systemauditor for in-process and vendorprocess  I have attended 3 days OBT Training program in 2010 at Garudnmachi from High Places.  I have attended Lean Six Sigma Green Belt Training Program from Qual Mind Global- Bangalaore.  I have attended Lean Six Sigma Green Belt Training Program from Qultima –Pune.  Attended SupervisorExcellency Program in 2012  Attended 1 Minute Manager Course  Converse with PPAP, APAP, FMEA, C&E, COPQ, DWM etc Hobbies:  Reading Books  Listening Music  Solving Puzzles  Watching Thriller movies Strengths:  Honest,Hardworking,  Strong orientation with customer needs / expectation  Can handle & communicate well with customer, vendor& internal team  Well regarded for interpersonal, written and oral communication skill.  Can handle multiple tasks simultaneously.  Ability to acquire and apply knowledge rapidly.  Can work independently with minimal supervision and contributes to a team Computer Skills:  Operating System: Windows  SAP Applications  Oracle Applications Thank you, for going through my resume. Place: Aurangabad – Maharastra Date: 20/12/2015 Arup Barman Roy