Contact Details :

Contact No.: 9654075008

Email address : hkathayat@gmail.com
Date of birth : 04 April 1985
Father’s Name : Kundan Singh Kathayat
Harish Kathayat Communication address : E-35, Street no.
11, Mandawali, Near Bal Vikas School,
Production & New Product Development Manager Delhi-110092

Profile
Rich experience of over 16 years in Production & New Product development. And having a production
exposure is add on to New Product Development with practical thinking from production point of view too.
Production: Production planning & TPM with a focused approach in achieving Daily/ Weekly/ Monthly
targets along with SQCDM control parameters.
Focused on sustainable growth of the deptt. and organization with a healthy environment & believes in a
teamwork approach.
New Product Development: Development and trial of new product in welding shop form Initial prototype
designing till product handover to production team.

Skills & Exposures

 Production planning and coordination.  Good exposure of problem solving & permanent
 Vast exposure to manufacturing of cars (SWIFT, countermeasure & sustenance.
SWIFT DZIRE, SX4, A-STAR,SKODA FABIA,  Fanuc Robotics teaching.
POLO, VENTO, BRIO, CITY, CRV, AMAZE,  Adaptable to any new job & always open to learn.
MOBILIO, CIVIC)  Team player with a good coordination along with
 Manpower handling with vast exposure to team members.
manpower handling issues.  System exposure :
 Exposure to New model implementation & Pre- 6 Sigma (Green belt : From TUV SUD)
trial inspection of new installed line (swift Dzire ISO 9001,
and A-star) with new process implementation. ISO 14001,
 Good quality exposure for defect free process. OHSAS-18001 (HIRA study)
 New Process implementation during product TPM
development stage. Lean Manufacturing
 Designing of the process layout.
 New Model activities/ NPD – Process preparation
& implementation in various events till maturation
and handover to production team.

Experience
April’2021 ~ Present (1.4 Years) Rhysley Pvt. Ltd., Faridabad, Haryana
(Manager – Production & NPD)

Key functional areas

  Production planning for next 3 & 6 months and its successful implementation.
 New project planning, identifying resources & successful implementation – Developed 2 new products as per the
customer’s requirement.
 Conduction of pre-production trials and identifying and eliminating of root cause.
 Functionality of all the departments and assigned task’s status check on daily basis.
 Quality report analysis with quality head.
 Process improvement activities and involving team in it.
 Multiskilling of the officers ensuring development of each individual.

Achievements
 Zero accidents in last 1 year (only 1 minor injury occurred)
 Production doubled with 1.3 times manpower only within 2 months (Planning & Implementation)
 Reduction of the rejection rate from 37% to below 5%.
 Shop floor layout planning and implementation.
 2 New product development in last 1 year and successful handover to the production team.

May’2012 ~ Nov’2020 (8.5 Years) Honda Cars India Ltd., Greater Noida, U.P.
(Assistant Manager – Production)

Key functional areas

PRODUCTION
 Daily production target achievement with quality for Metal finish line.
 Monthly business plan preparation for weld shop for Production and CAPEX
 Meeting GDPR (global direct pass ratio)/ DPR (Direct pass ratio) targets for weld shop.
 Safety coordinator for our shift (conducting weekly safety meetings)
 Robot teaching for new models (Fanuc robots) in coordination with robot teaching team.
 Management Business plan preparation & presentation for weld shop to Div. Head.
 Coordinator for NHC (New Honda circle) team formation & presentation.
 Coordination & conduction of Weld skill Olympics.
 Training coordinator for weld shop.
 Implementation & regular conduction of Zonal business plan (SQCDM basis)

NPD (New Product Development)

 New product development from Initial prototype phase and related process documentation.
 Knowledge of production hence utilisation of the same in maximizing the production efficiency during the
development stage.
 Identification & Controlling of the past observations and its successful control implementation.
 Process – Coordinator for CAPUP activities form 50K to 100K in welding shop.
 Pre-launch event coordination for Amaze, CRV and Honda City 5th Gen. (C-zone) – Dhankaku,
Hinkaku and Riyokaku events.
 Process Documentation freezing & controlling (PQCT- Process Quality control table, OPS, KQP,
MQS)
 New model development processes (welding shop) – Process development for Amaze, CRV, Honda
city 4th Gen and 5th Gen, WRV etc.
 PFMEA & DFMEA process implementation and checking.
 Line balancing for maximizing output during the Dhankaku event and finalizing it till the Hinkaku
event with maximized production output.

TPM
 TPM Coordinator for weld shop - Sustenance of TPM and its new pillar introduction and implementation in
welding shop.
 Initial core team member of TPM implementation in welding shop.
  Line balancing resulting in manpower reduction in welding shop by 8% (18 manpower reduction) (Using
JH and KK Pillar)
 5S drive to visual controls implemented in welding shop.
 Cost saving by implementation of the central cooling system in welding shop.
 Line efficiency increased from 73% to 89.5% by improving various processed (Using JH & KK pillar)
 Reduction in rejection – 11% door rejection which is reduced to 2% and the target taken was of 3% in
stage-1 (Using KK Pillar)
 Successful implementation of JH (Jishu Hozen) in welding shop - Results in reducing downtime of the
machines hence increasing the overall efficiency of the C-zone.
 Successful implementation of KK (Kobetsu Kaizen) in welding shop – Helps in resolving old pending issues
in line and improving the line efficiency and parallelly reducing the manpower.

Achievements
 Accident free zone: Zero accidents in Metal finish line from last 3 consecutive years.
 System making its implementation: of QD gate for controlling outflow and process improvement.
 System improvement: For controlling outflow of defects from final line (68% reduction).
 Successful implementation of face to face communication with line associates throughout the company.
 A part of the team for successful certification of OHSAS 18001.
 Sustenance of TPM and introduction of new pillars in welding shop with core team.
 NPD - Successful production handover of new models like – Amaze, CRV, Honda city 4th and 5th generation.
 Cost saving activities – Reduction in event car processing time (by improving the processes) – Honda city 5th
Gen. – 6 day’s time reduced in Dhankaku event and 8 day’s reduced in Hinkaku event.
 Process of efficiency increasing during the designing and development phase.

Feb’2011 ~ May’2012 (1.3 Years) Volkswagen Pvt. Ltd., Chakan, Pune

(Assistant Manager – Production)
Key functional areas
 Achieving daily production targets with quality and planning for whole month’s production.
 Monitoring of consumables and shop safety.
 Tact time optimization for polo and Vento line.

Achievements
 Permanent countermeasure for the A-Rank problem i.e. Spot over the frame number.
 Laser welding grinding wheel optimum utilization. (Cost reduction by 25%)

July’2006 ~ Aug’2010 (4.1 Years) Maruti Suzuki India Ltd., Manesar, Haryana
(Team Leader – Production & NPD)
Key functional areas
 Pre installation trial for new line/ model (Swift/ Dzire/ SX4/ A-star)
 Installation & complete Production trial for new line (A-star) – With Production engg. Team.
 Responsible for the production of complete A-Star.
 Improving line efficiency through process modification, robot teaching etc.
 Error proofing by implementing Poka-yoke system.
 General trouble shooting of welding robots, Handling robots and sealing robots.
 Good knowledge about jig’s-fixtures, PSW gun, SSW gun, robots and line automation.
 Presently working as a line in-charge of A-star line and responsible for achieving daily production
targets and various line improvements to achieve goal.
 Fanuc robot programming for all child parts.
 Tact time study & optimization.
 New model introduction in welding shop – Dhan, Hin and Riyo event coordinator from production end.
Achievements
 Problem solving manual made and successful implementation. (Still implemented in Maruti Suzuki,
Manesar plant)
 Spatter reduction activity in robotic line.
 NPD - Successful handover of the SX4, Swift Dzire and A-star to production team within stipulated
timeline.
 System improvement for manual sealer miss problem (Prob. eliminated)
 Fanuc robot training to new joiners.
 NPD - Successful line set of A-star in welding shop from production end.
 Special car made in weld shop for reflecting safety features in – Displayed in auto expo, Delhi
 Hourly process checking PA announcement system in welding shop (still implemented in Maruti Suzuki,
Manesar Plant – with my own voice recording).

Education & Certifications

2003~2006 Diploma in Mech. Engg. G.B.Pant Polytechnic,
Okhla Phase-3, Delhi

2003 12th (Science stream: PCBM) Govt. Sarvodaya Sr. Sec. Boys school,
Rani Garden, Delhi

2021 Lean Six sigma (Green belt) TUV SUD

2022 BBA (GPA - 8.2) AMITY University

MBA (Operations Management) Perusing (Narsee Monjee Institute of

Management)