DHANANJAY GUJAR

Contact: +91-9881464604/~ E-Mail: dhnugujar@gmail.com

Plant Head/Factory Manager Hi-Lex-India Pvt. Limited. Sanand Gujart

Operations/Maintenance/PE/Stores/Dispatch/Projects/Applications

OBJECTIVE
Goal-oriented professional, offering significant experience in operations for
enhancing Productivity, Delivering at Right Quality & Product Cost and ensuring Safety of People .
PROFILE SUMMARY
 Over 24 years of experience in areas of :
Operations Management Engine Assembly/Testing
Program Management Engine machining head, block
Budgeting (Expense/Capital/Manpower) Capacity Enhancement
Line Balancing New Product Dev./Launch
 Expertise as a Plant Head/Factory Manager in Engine / Auto Component Industry.
 Expertise in managing profit and Loss of overall factory.
 In-depth and hands-on experience in leading Engine assembly/Engine Testing
/Engine Machining Operations and ensuring compliance with quality/safety stand.
 Expert in executing new projects by APQP and APDP. Proven expertise in Value
Engineering and Value Addition.
 Comprehensive experience in numerous process improvement and operational
excellence initiatives based on Kaizen ,Six Sigma –Green belt and Lean
Manufacturing with respect to cost, resource deployment, time over-runs and
quality/safety compliance
 Achievement oriented professional with excellent people management skills.
 Expertise in evaluating different manufacturing strategy for machining.

CORE COMPETENCIES
 Leading entire plant operations (Engine /Auto components plant) from all aspects.
 Lead Engine operations from production planning, achievement of plan, execution
of shop-floor activities for existing products and the final execution for new pro.
 Leading teams for optimization of process parameters; initiating process
improvements for achieving bottom line objectives (P/L) & productivity targets.
 Identifying the areas of obstruction / quality failures and implementing system &
process changes for qualitative improvement, rejection control & productivity.
 Monitoring development of new products with respect to cost, resource deployment,
time over-runs and quality compliance; evaluating production progress & taking
adequate corrective actions.
 Leading teams for taking stringent quality measures and preparing necessary
documents to ensure compliance with pre-set standards viz. Lean Manufacturing,
Six Sigma, 5S, ISO 9001,QS9000 etc.

ORGANIZATIONAL EXPERIENCE

1) Hilex -India Pvt. Limited - (14 March 2016 till date)

Designation- Deputy General Manager / Factory Manager
Works as a Plant Head (Factory Manager) in Japanese MNC, Auto Component
Manufacturing,Tier-1 supplier of SMG Gujarat and HMSI,Group Turnover 550 Cr
Location -Sanand Gujarat.
Reporting to Vice President-West India Focus Factory

Achievements as Plant Head –

 March 14, 2016 to Feb 2017 – Plant setup from Green Field project.
 Feb17 – Customer (SMG & HMSI4F) approval taken by complying with stringent
customer audit (Systems/Process/ Procedure) requirement and SOP started.
 Feb17 – FY19 – Achieved monthly sales target FY17- 3.5Cr, FY18- 4.5Cr, FY19
–8Cr, for SMG and HMSI4F and handled steep Ramp up requirements.
 Feb17–March18 – Plant Productivity increased from 52 to 60 –by working on
stabilization of 4M’s for entirely new set up.
 March18–April19 – Plant Productivity increased from 60 to78-by allocation
study/Productivity monitoring/worst lines selection/ Yamazumi study /Micro level
study and Kaizen.
 Oct18 – Jan19 – Reduced material cost by appro.20 Lacs per month i.e. from
71% to 67 % of sales - by reducing process scrape/cable rejection/ VE/VA.
 Aug18–Dec18 – Reduced Labor cost by app.26 Lacs. i.e. from18.6% to13.6.
% of sales Budget 11.5% -by debottlenecking operations /increasing per shift
output/stabilization of manpower /reduction of OT hours and breakdown hours.

2) John Deere India Pvt. Ltd – 3 Years- (5th December 2012 to 15 Jan 2016)
Designation: Executive Manager II Engine Focus Factory
(Engine Assembly / T/ New Projects)
Reporting to Sr. GM Engine Focus Factory
 Handled responsibility of Operations Head Engine Assembly /T for 2 years by
leading a team of 8 Supervisors and 152 associates.
 Heads all new tractor projects for engine coming from Application Product
Delivery Process route and worked as Strategic Planner and Value
Engineering Manager for 1year.
Key Result Areas-Operations
 Achieving daily, monthly, quarterly and yearly P, Q, C, D and M targets.
Key Result Areas-Strategic Planner/Projects/Value Engineering Manager.
 Developing manufacturing strategy for machining options along with business
cases and discuss with Senior Leadership for taking investment decisions.
 Executing globally impacting engineering change proposals in engines by closely
working with Global Teams.

Achievements as Engine Assembly and T Head -

 “Best Safety FF Award’’–With major contribution70% from Engine Assembly/T

 “Distinctive Product Quality Drive”-Engine A and T –33% Reduction in
VAPPM, FPM rate reduced by 50% by deploying six sigma cultures on shop.
 Productivity-15% reduction in direct manpower by implementing line
deployment at 130 PACE in engine assembly and T. Achieved highest
Productivity in Pune Works.
 Achieved cost saving of INR. 25 Lac in FY13 by reusing engine parts of
dismantled tractors got Outstanding Team of the month award for this project.
 Delivery – Incidences of tractor sequence drop due to engine reduced by 50%.
Achievement as Application Product Delivery Process Manager

 Executed 5 new engine programs for supporting Tractors and harvester.

 Achieved DMC cost reduction target of 2.5 % of TIC app. 6 Cr.in ‘FY15 by VI.
 Conducted M or Buy Study for CY block and CY Head.
 3) MVM Limited, Chakan Pune: 1.9 years (22 March 11 to 4th December 12)
Designation: Manager Engine PU (Assembly/ T/ Machining/ Docking)
Reporting to GM Engine Transmission and Axle
Lead a team of 8 Officers 13 T/L’s and 250 associates.
Key Result Areas-
 Achieving daily, monthly, quarterly and yearly P, Q, C, D and M targets.
 SOP of new engine variants in all aspect of manufacturing (P, Q, C and D)
coming through APQP and MPDS roots.
Achievements in MVML
 Cost saving of Rs 10,000 per day by in house packaging of SPD engines.
 Best Productive PU award in F12 by improving Productivity by 17%.

4) Cummins India Ltd. Kothrud Pune: 9 years. (10th Dec 01 to 22 March 11)
Designation: Executive Manager Engine Assembly/Engine Performance.
Reporting to G.M Business Unit as “Section Head” in Engine A/Engine T
Key Result Areas-
 Responsible for meeting P, Q, C, D and M targets. Budgeting and monitoring.
 Continuous improvement in Engine Assembly and Engine T thru Six Sigma,
Kaizen, Ergonomics and seven steps Gemba Kaizen Projects.

Achievements in Cummins India Limited

 Completed Six Sigma Green Belt Project –“ Reduce NTBC Engine Taken
Down PPM due to Piston Seizure and Excess blow by from 9881 to 0”
Achieved Cost saving of 24.40 Lac per Annum
 Productivity increased by 100 % per bed per person by implementing Model
Test Cell and Autonomous Maintenance concept and achieved cost saving of
INR 45 Lac per annum by operating Engine T in one shift only.
 Won “Chairman Award” in Aug 10 in HSE category for Kaizen O tag project.
 Won “Spot award” for Ergo project on K19 Engine Damper/Pulley subassembly.

5) Mahindra & Mahindra Ltd Mumbai: 2.5 years (16th July 99 to 5th Dec 01)
Designation: Deputy Manager Engine Assembly / Engine Performance
Key Result Areas-
 Daily production and schedule adherence to target plan in Tran lift Automated
Electrified Monorail sequential engine assembly.
Achievements:
 Reduced rejection at engine performance from 40000 PPM to 5500 PPM.
 Achieved cost cutting of INR4 lacs / year by implementing alternative solution.

6) Bajaj Tempo Ltd. Akurdi Pune 35. -6 years (10th Aug 93 to 7th July 99)
Designation: Engineer (QC- Engine Assembly& Performance)-6 Years
Achievements:
 Reduced % rejection at assembly from 12.5 to 2.0 at performance 16 to 1.5%
EDUCATION

 DME-1993 , AMIE(Eq. to Grad) from Institution of Engineers (I) in 04 –I class

 PGDBM –Finance-Pune Uni. -2017 –Scale 10 Grading System – Achieved -8.1

Date : 28th August, 2019 Total Experience : 24 Years