MANISH KUMAR
manishsinha.ism@gmail.com;
Key Skills
Total Quality Management
Lean Six Sigma Black Belt
Operational Excellence
Supplier Quality Management
New Product & Parts Development
Stakeholder Management
Strategic Planning & Management
Design Thinking
Leadership & Communication Skill
Career Timeline
Jul’03 to May’10
Tata Hitachi Construction Machinery Co. Pvt. Ltd., Jamshedpur
Growth Path
Jul’03 to Jun’06 Graduate Engineer Trainee (Assistant Manager)
Jul’06 to Jun’09 Manager
Jul’09 to May’10 Senior Manager
manish_mensch@yahoo.com
09955133737
http://in.linkedin.com/in/manishkumarsinha
Expertise in Quality Management / Operational Excellence;
targeting senior level assignments in Manufacturing industry
Profile Summary
14 years of rich experience in Quality Management & Operational Excellence
Currently associated with Tata Hitachi Construction Machinery Co. Pvt. Ltd. as
Jamshedpur Operations Quality Control Head
Lean Six Sigma Black Belt
Certified Lead Auditor of ISO 9001:2015 & TBExG (Tata Business Excellence Group)
certified Assessor of Business Excellence
Skilled in Product, Process, Customer & Supplier Quality Management, New Product
and Component Development, QMS, SPC/SQC, APQP, PPAP, VA-VE
Experienced in Hydraulics, Manufacturing Processes, Mining Machinery
Successfully executing reliability and value engineering projects based on voice of
customer by leveraging benchmarking, gap analysis and mitigation
Proficient in analytical tools, problem-solving approaches, process improvement,
anticipatory failure identification & prevention
Outstanding communication & leadership skills that have been put to use in
effectively resolving problems & promoting a positive work environment
Tata Hitachi Construction Machinery Co. Pvt. Ltd., Jamshedpur
Growth Path
May’11 to Aug’13 Senior Manager
Sep’13 to Mar’16 Assistant Divisional Manager
Since Apr’16 Divisional Manager (QC Head, Jamshedpur)
Since May’11
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Knowledge Purview:
Operations and Marketing Management Graduate from XLRI
Operational excellence
Tata Business Excellence Model (based on Malcolm Baldridge Criteria, USA)
QMS: ISO 9001:2015 Certified Lead Auditor
Lean Six Sigma Black Belt (TUV-SUD)
Design Thinking
VA-VE, PFMEA, VSM, APQP, PPAP, SPC/SQC expertise
Knowledge of best practices of both Tata & Hitachi Groups
Hydraulic equipment manufacturing & testing
Problem solving tools (DMAIC, PDCA, G8D, 7QC, FTA, Design of Experiments)
COPQ & control
Gear box endurance testing
Indigenization of gear boxes
Hydraulics expertise

Key Result Areas:

Leading in-house manufacturing quality as well as supplier quality
Ensuring value addition on SQCD (Safety, Quality, Cost & Delivery) aspects by working in sync with the senior
management & operations partners
Improving reliability and field performance of manufactured mining and construction machineries
Convening manufacturing quality CFT’s (Cross-Functional Teams) across all 3 Plants (Jamshedpur, Kharagpur &
Dharwad) and reporting to QA Head, VP & MD
Organizing drive for QA process & best practices standardization across all 3 Plants and reporting to QA Head & MD
Assessing manufacturing facility quality based on Global Quality Diagnosis (GQD) inputs- one of the best practices
followed in Hitachi Group
Performing various activities such as annual quality budgeting, recording & publishing quality BSC & KPI’s & ST/LT
strategic planning of quality management
Developing subordinates for superior performance by cross-training, mentoring & motivation
Synchronizing the team with organizational vision, mission & objectives by leveraging cascaded balanced score card
& KPI’s with periodic reviews
Providing feedback to the process associates based on quality audits and rendering suggestions for improvement
Implementing various operational excellence techniques and entailing identification of opportunities, analysis of data,
conduction of tests, cost benefit analysis & implementation

Highlights:
Worked with CXO-level leaders to meet their expectations such as devising Quality Guidelines, Supplier Quality
Manual, New Component Development Manual, Total Management of Quality Metrics, Quality-linked Wages
Structure, e-platform for spares sale, m-platform for SAP (in conceptual stage)
Benchmarking best practices such as Global Quality Diagnosis, documentation of key Enterprise Processes, Proactive
& Reactive Audits, Supplier Hand-holding, Design & Quality Review during New Product Development & drove
necessary changes for their implementation
Formulated Quality Guidelines which improved customer quality management in terms of defect prioritization,
response level to field failures and anticipatory defect prevention mechanisms
Reduced Commissioning defect rate (first 100 hours) by 33% over FY 16-17 by applying assembly diagnosis, factor
tree analysis, training, evaluation and improvement.
Reduced warranty defect rate (first 2000 hours) by 32% over FY 16-17 by applying Design Review & Validation,
Supplier Approval and first hand capturing of VoC
Reduced the rejection ppm rate by 50% over FY 16-17 through measures such as rejection analysis, supplier
capability assessment, gap identification & mitigation, hand-holding, 4M Change Authorization Process, front-loading,
technical discussion, GQD audits, parts approval, factory approval, etc.
Performed gap identification & mitigation which led to 20% reduction in zero-hour defect occurrences in 1 year.
Implemented deep-dive analysis & systematic problem resolution which reduced warranty defects on Transmission
Devices from around 1% to 0.1% in 3 years
Indigenized gears & gear boxes of several excavator models in collaboration with Hitachi (HCM) resulting into a cost
saving of around INR 60 million per annum
Formulated & implemented Supplier Quality Manual and New Component Development Manual

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 Devised & implemented the following:
o Total Management of Quality Metrics for key aggregates
o SAP-based measuring instrument calibration system in 2017
o Quality Review system for change point management in 2016
o Air Leak test setup for gear boxes with locally available material in 2016
o A practicable Tool Life Management Program in 2015
o SQC-based Program to monitor Cp/Cpk on periodic basis in 2015
o Online server-based trigger system to maintain calibration of measuring instruments in 2014
o UV-light based leak detection setup for detecting hydraulic oil seepage/traces in 2013
Developed parameters for quality-linked component of wages of workers & supervisors which helped organization in
instilling sense of quality ownership in the workers and supervisors and thereby improving organizational
performance on quality aspect.
Played a key role as a member of different NPI projects in developing components for new machine models
Created & implemented new & low-cost pre-commissioning testing process of gear boxes with locally available
material which saved cost by INR 0.5 million in terms of set-up cost and additional benefits in terms of reduced
warranty cost
Analysed & mitigated the gaps which improved quality level of casting, forging & machining vendors by 50%
Revised and reset the Dumper Rear Axle Test Rig in-house which improved testing effectiveness & defect detection
capability in organization with resultant improvement in dumper field performance- 2017
Conceived hydraulic drive test bench for leak & performance test of hydraulic gear boxes - under implementation
Conceived & established the layout of a versatile Machine Test Track in Tata Hitachi- Kharagpur Plant in 2010
Executed QM Infrastructure, Quality Systems & SAP QM Module in THCM's new plant at Kharagpur in 2009
Contributed as a member of CRISP (A Cost Reduction Project guided by McKinsey) & achieved 15% reduction in the
cost of production of dumpers in 2009

Certifications:
Lean Six Sigma Black Belt
Trained on Design Thinking
BSI (British Standards Institute) certified lead auditor of QMS (ISO 9001: 2015)
BVQI (Bureau Veritas) certified internal auditor of QMS (ISO 9001:2008)
TBExG-certified Assessor of Tata Business Excellence Model (TBEM), adapted from Malcolm Baldridge National
Quality Awards Program, USA to assess Corporate Quality Level
Trained on OHSAS 18001:2007 HIRA (Hazard Identification & Risk Assessment)

Educational Details:
PG Diploma in General Management- Operations & Marketing (Executive MBA) from XLRI with 5.77/8.00 CGPA in
2011
B. Tech. in Mechanical- Mining Machinery from IIT (ISM), Dhanbad with 4.55/5.00 CGPA in 2003

Academic Achievement:
Awarded Yule’s Medal by The Mining, Geological & Metrological Institute of India (MGMI) for Excellence in Academic
Performance in 2003

Personal Details:
Date of Birth: 1st March 1978
Languages Known: English & Hindi
Present Address: Flat# P-17/5, River View Colony, Telco, Jamshedpur (Jharkhand) – 831004
Permanent Address: S/o Sudhanshu Kumar Sinha, Moh. - Noongola, SDO Road, Hajipur (Vaishali, Bihar) – 844101

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