Assistant Manager, Press Manufacturing Engineering Division

Suzuki Motor Gujarat Private Limited

July 2018 - Aug 2022

Projects Undertaken at SMG:

• New Product development:
  • Supported in achieving production targets by identifying machine related modifications and completing it before the start of vehicle’s mass production.
  • Design of material handling skids, pallets and jigs for New Vehicle Model die tooling. Acted as a point person for standardizing designs of various material handling equipment.
  • Supported ramp up phase of Baleno, Swift and Dzire models (1000 vehicles/day production volume models) with timely delivery of the required skids, pallets and fixtures.
  • Ensured customer feedback after handover is implemented on to the next car model preparation by revising standards and maintaining issue tracking lists.
• IOT System:
  • Developing a SCADA based system for collecting quality related data from Press Machine with the end goal of integrating industry 4.0 features.
  • Analyzed data collected from the IOT system to establish Process control methods like Statistical process control to generate system based alarms for defective parts.
• Crack Monitoring System:
  • Implemented a vision based sheet metal crack detection system where 20 cameras were used to detect surface defects on sheet metal car components.
  • Performed user acceptance testing of the software and hardware to recommend further development and modifications in image recognition, capturing and storing codes.
• Integration of Crack Monitoring System and Press machine:
  • Applied MODBUS protocol for integration of the Press machine with the above system.
  • Programmed Press machine Digital I/Os for development of part recipe change management software and successfully tested synchronization with Press machine.
• New Facility Establishment:
  • Instrumental in establishing a green field plant of 250,000 vehicles/year.
  • Handled 50+ vendors working under the same roof for Installation & commissioning of Servo Press Machines and other allied equipment of New Stamping Press Shops.
  • Streamlined progress with internal stakeholders like the Civil and Utility team to achieve the target of commissioning as per the timeline.
• Particle Counter System:
  • Installed Laser based particle counters at various locations and conceptualized the PLC network design.
  • Assessed particle count and to establish clean rooms in areas of high importance and high contamination inside the Press shop to achieve defect rate reduction.
• Stamping Press Final Goods Traceability system:
  • Devised architecture and flow of a system which integrated the vehicle tracking data like VIN with Press shop raw material data into a Centralized repository for back tracing.
  • Coordinated with 3 different shop production teams in getting feedback during design and benchmarking of the system.
• Promotions: Joined as Graduate Engineer Trainee in 2018, Promoted to Junior Manager in 2019. Promoted for the second time as Assistant Manager in 2020.