Pawan Kumar 

Mob: +919876345533,E Mail:dhankharpawan12@gmail.com,
Add: IND330,Parsavnath Eden’s society Alpha-2, Greater Noida U.P  
In quest of assignments in Manufacturing operations, Tool development, Supplier Quality improvement,  
Process Engineering, Quality Management and TPM with an organization of repute

Plant Head - Manufacturing

BE. Tech (Electronics & tele communication)

PROFILE
A young smart energetic professional, Six Sigma Black Belt having rich experience of 21years
In Production Operations, Process Planning, Quality assurance, Supply Chain Management,
▪ Excels in directing & controlling manufacturing operations & experience of working in varied
industrial segments.
▪ Expertise in implementing changes to machinery and equipment, production systems and methods of
working, Direction of quality control inspection systems & reporting procedures
▪ Proven abilities in handling a work force of 650 manpower & complete plant operations entailing
planning, in-process inspection, resource utilization, Maintenance, quality management &
manpower management
▪ Actively involved in developing new business, growing revenue & profit and forging strategic
alliances
▪ Possesses expertise in cost analysis, capital budgeting and feasibility studies for new projects and
ventures
▪ Accountable for ensuring that progress & cost control strategies are in place and acted upon according
to the Priorities as well as assuring availability of sufficient human & financial resources to carry these
out
▪ Well versed with Six Sigma, 5S, 3R, Fi 11, OEE& TPM.
▪ Responsible for coaching and mentoring Green Belts, training Lean Sigma tools and methodologies,
coaching project champions and process owners, and developing future leaders of Lean Six Sigma.
▪ Expertise in handling products like Color television, LCD monitor, Personal computer , PCB line,
Room Air Conditioners, washing machine, Air cooler, Ref compressor and equipment’s like Jigs,
Molds Changeovers, etc.
My core competencies can be summarized as:
Plant Management Strategic Planning Production Management
Process Planning Quality Management Production Optimization
Cost Reduction Production Planning & Control Lean Manufacturing
PROFESSIONAL EXPERIENCE
Boyd Corporation (USA Based MNC) - As Plant Head (GM operation) Aug’20 till now
Boyd Corporation is a global leader with more than 90 years of experience in advanced sealing,
Thermal management, and protection solutions for the world's most demanding applications.

Key Responsibilities is:

▪ Operational profit and loss responsibility for the manufacturing facilities.
▪ Autonomous role with day-to-day control of manufacturing activities.
▪ Completely responsible for Plant Operations such as Manufacturing, Quality, Sales & Operations Planning
(PPC), Supply Chain & Warehouse management, Domestic & International Logistics, Lean, Creating &
managing budgets.
▪ Customer focus & growth mindset. Understanding customer requirements, concerns and promptly resolving the
issues and enhance customer satisfaction
Major Role:
Production Planning: long with PPC discuss three month production plan for main line; make internal plan for main line
Production in accordance with three month plan and break plan into weekly and daily targets; attend daily production
Meeting and analyze daily production targets to arrive at model wise optimum sequence of production in coordinate
With Manager and Shift Engineer
Manufacturing KPI / Production Target: Monitor all lines on daily basis to ensure compliance on all company defined
Manufacturing standards and parameters, Production KPI management: UPH / UPPH / Innovation activities /
Yield rate.
Quality Control:  Analysis of manufacturing part & process defects, Standard work implementation.
Controlling inspection guides and parameters, Quality KPI management: LQC PPM/PDR / FFR / OQC lot rejection
Production Management: Manpower deployment. Implementation of WI / QCFC, 4M control & special process
Monitoring. Line balancing monthly review and ST management for main lines
New Line Introduction:  Get information of increase in production capacity including setting up of production new line;
assist production Head in manpower planning for the same.
New Model Introduction / Model Change:  Coordinate with R&D to introduce new model, Plan re-deploy
Manpower to the changes made in the line .Model completion in NPI. ( ST / FMEA / Process review )
Safety:  Ensure all safety standards are implemented in plant & ensure all safety guidelines are followed in carrying out
Work on the line.
Manpower Management: Skill up gradation of Manager and supervisor. Regular training impartation to supervisor &
in charges for production & quality systems.
Innovation Activities: Managing various innovation activities including 6 sigma, suggestion scheme, and Quality Projects.

PREVIOUS PROFESSIONAL EXPERIENCE

Hero motors - A Division of hero cycles. - As Plant Head Oct ’18~ Aug’20
Hero Cycles is the largest cycle manufacturer in the world. The company has a manufacturing capacity of
7.5 million Bicycles per year, with its unit in Ludhiana (Punjab), Bihta (Bihar) and Ghaziabad (UP).
Achievement
o Electric Cycle production increase from 50 to 500/day.
o Aluminum welding machine OEE increase 15% thru innovation.
o Rejection reduce from 5% to1.5 % thru process improvement.
o Paint shop capacity increase ,to increase the Hanger & optimize conveyor speed - cost saving-30 lacs/year

Aditya Thermo pack Private Ltd. - As Plant Head Jan-15 ~ Oct-18

Aditya thermo pack Pvt. ltd is leading manufacture supplier of packing materials thermo cols molds product,
Thermo coal block, EPS beds, having the capacity of 200 ton shape molding & Plastic injection molding parts.
Having15 molding machine (180ton to 660ton).One tier approved vendor Company & certified ISO 2001&1401.
Major customer is: LG electronics India Pvt. Ltd, Samsung electronics India Pvt. Ltd. Starion India Pvt. Ltd.
Vimal Plast India Pvt. Ltd., Symphony India Pvt. Ltd. Secure meters & Aone meters Pvt. Ltd.
Achievement
o Plant Turnover increase 21 Cr to 155 Cr within three years.
o Molding machine OEE increase 20%↑thru innovation.
o Rejection reduce from 8%to2%thru process improvement
o in house EPS mold modification & new mold manufacturing capability - cost saving-10lacs/year
o Sub assy area capacity increased 50%↑ thru on line assy preparations
o Petcock consumption reduce from 2kg to 1.5 kg CI-Rs4.5lacs/month
o Symphony cooler line setup & achieve daily production of 850cooler/day
o SMT (Siemens &fuji machines) production line setup with the capacity CPH 52K/hour in JQH & Elcom system
o Three PCB & charger assembly line setup with the capacity 2500/day
PREVIOUS PROFESSIONAL EXPERIENCE
LG ELECTRONICS INDIA LTD, GREATER NOIDA- As Production head Jun-99 ~ Dec-14
A wholly owned subsidiary of LG Electronics, South Korea, established in 1997 and manufacture consumer electronics and
household appliances.
ACHIEVEMENTS;
-CTV, Monitor, LED line Production in charge
▪ Manufacturing line capacity up 50% :
o CTV line Tact time reduction from 10 sec to 6 sec by ECRS
o Air condition cycle time reduction from 22 sec to 18 sec.
o Sub Assy Line Productivity imp by 15% by Re Layout
o Implementation Of Set Part System On Line
o Implementation of Outsourcing modules MP reduction (16 no’s).
o Setting up manufacturing systems at EMS.
o Implementation of routine material feeding concept & SPS system
▪ Quality Improvement Through TDR And 6 Sigma :
o LQC PPM reduced by 20%. six sigma & DI done on chronic issues
o Six Sigma Project –on Q issues – Yearly based
o ESD failure PPM reduction by 30% ( detection enhancement & design review )
o Fool proofing for Q defects - Monthly based
o Fast execution projects – Monthly based
Role & Responsibilities: (FIT team leader – LCD monitor/ Air con Production )
o Leading air-con production activities.( RAC , CAC & HE lines)
o Managing delivery, line & field quality, manufacturing cost matrix.
o 4M management.
o Shop floor Innovation up keep thru Fi- 10 .
o Leading Loss Management drive LE 10 .
o Leading TDR / FRP/ Six Sigma initiatives.
o Coordinating Vendor Quality management drive.
o Team size of 1 DM , 1AM, 14 Engineers, 2 supervisors, 164 workmen.
o Manpower competence development in line with GCGP culture.
ACHIEVEMENTS
o Establishment of all facilities for compressor manufacturing and production capacity increase from 640 sets/Hr to 900
sets/Hr.
o Refrigerator R1 line production capacity increase from 150 sets/Hr to 200 sets/Hr.
o Creating interchange ability for all products manufacturing setup including conveyor lines (Productivity imp by 70%)
o Door foaming Tact time reduction from 24 Sec to 18 Sec by converting manual processes to automatic processes.
o Establishment of new conveyor lines- 3 nos.
o Addition of vacuum, Recovery and Oil Charging machines (6 Nos.)
o Set Up For LQC, FQC And OQC On Line.
o Addition of Automatic Dummies On Line
o Set Up of All The Process And Quality Parameters On Line.
Professional Development Opportunities:
o Six Sigma Training. Certified Black Belt. July 2004
o ISO TS/16949, SPC, MSA, EMS 14001, Quality Circle, Six Sigma, and Lean Manufacturing
o Lean manufacturing workshop (Quality Growth Services).
o ISO 9001:2000 Internal Quality auditors Training Program
o Training In FRP/ TDR.
o training In Manufacturing Concepts conducted by CA
o Managerial Skill Development.
o ESD management training
EDUCATION
o Six Sigma Black belt (Jul’ 2004), Certified by LGE Korea
o Diploma (Electronics), Industrial training institute Sonipat (Haryana)
o B. Tech (Electronics & Telecommunication)
o IT Literacy: MS Word, Excel, Projects and Power point

PERSONAL DETAILS
Father’ Name : Sri Jaikuwar
Permanent Address : VPO-Khubru,Teh-Ganuar, Sonipat, Haryana – 131101.
Date of Birth : 30-Dec-1975
Passport : B00555

(Pawan Kumar)