1. Santosh Shelake Contact
Tel : 9561111052
e-mail:
santosh.shelake@gmail.com
TITLE BE (INDUSTRIAL AND PRODUCTION) WITH 8+ YRS OF EXPERIENCE IN PROCESS
DESIGN/LEAN METHODOLOGIES
PROFESSIONAL EXPERIENCE
 A competent professional having 8+ years of domestic and overseas experience in Process
Planning, Industrial Engineering practices, Virtual manufacturing, Lean concepts and
Remanufacturing processes.
 Currently working in John Deere Technology Center as Sr. Manufacturing Engineer.
 Hands on experience of working on Assembly Process Planning, Tooling Identification &
Ergonomic validation for New Product Introduction Programs, Virtual Audits, Time
Standards, 3-D Factory Design & Layout Optimization using Visualisation Mock up, Vis-
Jack, Classic Jack, Factory Cad, Wplanner ( Based on MTM ), Dynamic Line balancing using
Simulation tool
 Proficient in Mistake Proofing, Lean tools like 5-S and Kaizen, Value stream mapping and wide
range of continuous improvement programs.
 End user in SAP Production planning module for John Deere Power System units.
 As an Industrial Engineering point of contact for the team, conduct methods audits for accurate
standards.
PROFESSIONAL TRAINING & SKILL SET
 Undergone John Deere Corporate driven Industrial Engineering Experts training.
 Undergone Lean Practitioners training-provided by BMGI. Completed 3 Lean projects for John
Deere Pune factory.
 Undergone Six Sigma Green Belt training.
Key skills
 Modeling : Pro-E, AutoCAD
 Simulation : Vis Mockup, Vis Pro, VisJack (Ergonomic Evaluation), Classic Jack (Advanced
Ergonomic Evaluation and Simulation) , ALiSS Simulation (Discrete event simulation), ICIDO,
Factory Flow
 Animation : Seemage
Education
2000 to 2004 BE in Industrial and Production Engineering - “First Class”
Gogte Institute of Technology (Visvesvaraya Technological University),
Karnataka
1999 to 2000 Pre-University (12th) - “First Class”
JA Junior College. Athani, Karnataka

2. Work Experience
John Deere India Pvt Ltd (Sept 2009 to till date)
Sr. Manufacturing Engineer.
Role :
 Have been performing the role of IE (Industrial Engineering) since Feb-12
 Providing EPDP (New Product Introduction program) support for Engines, axles and
Transmission factories.
 Making a sound project execution plan and allocating suitable resources.
 Developing Skill set required for the new process and identifying the trainings required for
resources.
 Line balancing & line design processes.
 Engineering Change Management for Engine assembly processes.
 Coordinating the project activities and drawing specifications with the plants to ensure
BOM is as per the specifications.
 To coordinate with inventory, logistics for proper consumption of BOM.
 Routing the BOM.
 Facilitating proto type builds by providing virtual build solutions (Animation, factory flow,
ergonomic analysis etc)
 Analyzing the need for the new assembly tools.
 Analyzing reach ability & assembly ability through E-build.
 Tracking team’s productivity & quality.
Major Projects Executed :
1. 944 Wheel loader’s final drive EPDP (Enterprise Product Development Program) :
Unit: Motores John Deere, Torreon, Mexico
Responsibilities:
 Designing of the process through GSOE (Graphical sequence of events),
 Conducting Virtual build sessions at various phases of the EPDP (NPI) process,
 Identifying the tooling requirement and coordinating with Tool design team to develop
required tools & fixtures
 Collaborating with Quality team and work on developing PFMEAs.
 Validate tools, fixtures, facilities and the factory equipment by means of animation.
 By means of Ergonomic analysis, provided solutions to improve working conditions &
safety,
 Make sure that Enterprise Industrial Engineering standards are followed by setting the
accurate labor standards using Enterprise process planning tool – Wplanner.
 Identifying VAs and NVAs and work on reducing them.
Major accomplishments: Most of the tools, fixtures & material handling equipment were
designed & implemented with minimum post design changes. Improvement areas (process,
tools, ergonomics etc) identified during lab build & proto build were well documented &
improvements were implemented before the physical build.
2. EPDP support for OX_large_axles:
Unit: Motores John Deere, Torreon, Mexico
Activities Process feasibility study for the new axle. Identified interferences with the
existing equipments (Press, drivers, lifting tools, test benches etc) for the new axle.
Completing GSOE, validating the process & tools through animation, Ergonomic analysis,
ALiSS Dynamic simulation, updating W-planner process planning, and Factory flow analysis.

3. 3. Engineering Change Managemenr :
 Assembly Planning activities (ECM & VA) for engines used for Locomotives, Marine and
commercial purpose.
 Generating BOM routing in SAP.
 Creating alternate hierarchy in Vis mockup as an input for Graphical Sequence of Events
of Engine assembly.
 Line balancing & line design activities.
 Identifying the tooling, spare part packaging requirement for the new components &
defining the same.
 Suggesting factories to standardize parts & standardizing the torque used for different
hardware.
4. IE roles and responsibilities:
 In coordination with JDPS IE platform lead, prepared an action item on the IE scorecard to
bring all the factories up to the Deere standards.
 Have taken knowledge sharing sessions for the team, making them aware of common
mistakes that can happen while setting the time standards.
 Clear training plan for each individual team member for IE has been prepared & the
matrix being tracked.
 Participated in Enterprise level projects to improve the Standard Data Application process.
 Contributed in setting up JDTCI-Manufacturing Lab. Developin a training module for
Industrial Engineering, to be set up in the lab.
5. Remanufacturing:
Unit: John Deere Reman, Springfield, MO, USA.
Roles and responsibilities:
 Incoming core (Used parts) inspection method analysis.
 Evaluating current disassembly methodology and suggesting improved more efficient way
of disassembling.
 Identifying NVAs in Core treatment process after the disassembly (Cleaning, blasting,
baking etc)
 Identifying NVAs in Parts identification & storage process.
 Overview of inspections process.
 Analyzing the current methods in Machining & salvaging process and suggesting
improvements
 Auditing correctness of SAP BOM and its periodic maintenance.
 Creating Work Instruction for assemblers to ensure mistake proofing.
 Identifying tools and fixtures by benchmarking other John Deere factories.
 Implementing John Deere Industrial Engineering standards.
6. Engine test cell safety & productivity improvement project
 Using Lean tools, identified wastes in this area.
 Working on a breakthrough concept of match-plate which will address both safety and
productivity concerns.
 Using Industrial Engineering concepts, developed methods of rigging and de-rigging in our
Argentinian factory. Same thing will be benchmarked for other factories.
Department level activities at John Deere
 Member of Technology and Innovation Team- Currently working on Pune factory innovation
project.
 Part of a team which is working on setting up a state of art Manufacturing Lab for training
purpose.
 Part of Enterprise Industrial Engineering Experts team.
 Developed “IE Methods development” training module in JD R&D lab and I am a trainer for
this module.

4. MAHINDRA SATYAM BPO HYDERABAD (MAY-06 TO AUG-09)
Client: Caterpillar Inc. USA
Role :
 Processing Engineering changes.
 To coordinate with inventory, logistics for proper consumption of BOM.
 Creating Work Instruction for assembly operations as per Engineering Changes.
 Setting of time standards: - Setting Time Standards for different operations
Of assembly line using Centralized database Tool - “CDSA” (based on PMTS)
Also suggesting & documenting best Practices for operation methods.
 BOM generation
 Hands on experience on Vismockup, Visview.
CATERPILLAR MOSSVILLE ENGINE CENTER-ONSITE PROJECT:-
As a Manufacturing Engineer, involved in Assembly Planning activities.
Roles & responsibilities:
1. Coordinating offshore Planning Team for smooth documentation of Post Assembly process for
variety of engines.
2. Coordinating Engineering Change Management activities & participate in implementing the
ECMs on floor.
3. Discuss with Design Engineer regarding latest Engineering Changes on upcoming engines.
4. Setup the Engine masking line.
5. Completed Visual Aids project for ATA (After Test Assembly) assembly line.
6. Completed a project on organizing part locations according to stations in ATA assembly line.
7. Actual Time Study and Line Balancing
8. Taking complete responsibility of visual aids for each engine model.
9. Validating the wash preparation, paint protection, after paint assembly process.
10. Implementing Visual Aids for paint protection & after paint assembly line.
11. Been a part of the team in setting the process for the new Tier IV engines.
12. Coordinating with logistics for availability of material for assembly as scheduled.
13. Optimizing part locations for commercial engine assembly area.
14. Setting up stall build area for Marine engines for selected assembly processes.
Personal Details
• Date of Birth : 16/11/1982
• Sex : Male
• Languages : English, Hindi, Kannada, Marathi, Telugu.
• Nationality : Indian.
• Visa : B1/B2 valid up to 2017, L1 B