Automotive

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Launch Manager

Project Length

  • 12 Months

 

Objective

  •  Ensure the successful launch of L551

 

Issues to start with

  • 3 Major projects started at the same time + Transfer of existing IP assembly to new AGV line & plant

 

Plan to fix it

  • Supported Programme Management in the Implementation of L551 Armature and Console Assemblies into new Manufacturing Facility.

  • Supported on the line L551 pre-production builds T1 & T2.

  • Held daily project meetings with Manufacturing Launch Team.

  • Updated, Reported and Monitored on project status weekly/ Monthly with SLT.

  • Attended and contributed regularly to DFM & DFA activities with JLR.

  • Attended and presented at monthly meetings with JLR Supply Chain Management.

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Issues on the way

  •  Introduction of AGV line for existing models was taking up all the resource's

 

Result

  •  L551 T1 & T2 Builds Completed Successfully

Senior Project Manager

Project Length

  •  6 Months

 

Objective

  • Identify and Implement Cost Reduction Programmes Cross Car Line JLR

 

Issues to start with

  • Vehicle costs & Kg's were much higher than competitors vehicles

 

​Plan to fix it

  •  Identified and developed cost-saving opportunities on materials across D8, D7U and D7A vehicle platforms,

  • Carried out one to one reviews to explore possible cost saving opportunities with the Should Be Cost Engineers

  • Developed a product-focused outlook to line walks, emphasis being on quality rather than quantity of ideas, endorsed a small team approach.

  • Organised one to one Plant line walks at FA2, Halewood and Castle Bromwich

  • Recorded opportunities on to company wide portal

 

Issues on the way

  • Reluctance by Design Engineers to consider changes to their designs.

  • Being able to engage with C of E managers on savings which equated to less than £60k per annum

 

Result

  • Spearheaded £5M per annum in cost savings by setting up a system to track the progress of cost-reduction ideas in iHopper and CCR at various milestone stages.

Car Disc Brake
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Launch Manager

Project Length

  •  6 Months

 

Objective

  •  Defining of process steps to build Front and Rear seats for the New Mini Project for BMW.

 

Issues to start with

  •  New project for a New Customer in the UK

 

Plan to fix it

  • Attend regular core team meetings in Munich.

  • Work closely in Bad Abbach with Process and Design Engineers to ensure design for manufacture.

  • Produce Preliminary Process Flows & FMEA's

  • Simulate complete build using edited video

  • Introduced Faurecia best practices into Production Process

 

Issues on the way

  • Fine tuning of manual processes to avoid RSI Issues

 

Result

  •  Initial build phases completed in time to meet Industrialisation start date

Launch Manager - Seating

Project Length

  •  16 Months

 

Objective

  • Ensure ZS44, ZM44 & ZS 44 Projects for Nedcar were launched on time

 

Issues to start with

  •  Factory set up in Holland as a brownfield site

  • Management and Staff were being transferred from an Exhaust Plant to start up a seating plant

 

Plan to fix it

  • Develop and introduce KPI’s for monitoring Project Status.

  • Introduce visual management system to track Project Progress.

  • Introduction of autonomous cells into manufacturing.

  • Coach and mentor New management team in Faurecia Excellence System, Production System Efficiency and Employee Empowerment.

 

Issues on the way

  • Employees from Exhaust plant didn't have the dexterity to build seats

 

Result

  •  Successful launch of 3 projects

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Launch Manager - Seating

Project Length

  •  3 Months

 

Objective

  • Ensure MCC Project for Daimler Chrysler adhered to Customers timing.

  • Implement best practice lean principles

 

Issues to start with

  • Location Pierrepont, Eastern France

  • Language barrier

  • Different cultures

 

Plan to fix it

  • Industrial Planning of logistics/ warehouse to reduce stock and resources.

  • Implementation of a small train and small box to reduce line side stock.

  • Industrial planning and the introduction of a flow line from a modular seating build

 

Issues on the way

  • Continued resistance from Management

 

Result

  •  Flow line and Lean principles adopted in to manufacturing cell

Production Manager - Seating

Project Length

  •  4 Months

 

Objective

  •  Responsible for all aspects of production management & control

 

Issues to start with

  • High Absenteeism

  • Running on 2 Shifts

  • Unable to achieve customer run at rate criteria

  • Poor right first time

 

Plan to fix it

  • Monitor productivity & achievement of targets against key objectives

  • Co-ordinated production planning & production scheduling activities

  • Introduce controls to reduce absenteeism

  • Recruit & train 3rd shift

  • Create measles chart to target hot spot quality issues first

 

Issues on the way

  • Having to play catch up on lost production during the week

 

Result

  • Absenteeism reduced from 15% to 4%.

  • Run at rate achieved

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Launch Manager - Interior Trim

Project Length

  •  18 Months

 

Objective

  • Industrialise New Injection Moulded Products and Assemblies for Corolla & Avensis in the UK

 

Issues to start with

  •  Low Pressure back injection was a new process to Fradley

 

Plan to fix it

  • Buy Off Tooling and Assembly processes in Europe & Japan.

  • Liase between Development in Meru and Fradley

  • Ensure Product Validation is achieved

  • Capacity Planning for 13 Injection Moulding Machines

  • Capital Justification and purchase of Special Purpose Equipment.

  • Introduce dedicated resource to develop & Industrialise Low Pressure Back Injection process.

 

Issues on the way

  • Developing Tooling and Products to ensure successful de-mounting of parts with robots

  • Tuning processing conditions to optimise the process.

 

Result

  • Products successfully launched into serial Production.

Production Manager - Interior Trim

Project Length

  •  12 Months

 

Objective

  •  Transfer production from Germany supplying UK customers to a UK location

 

Issues to start with

  • Factory set up in UK as a greenfield Site

  • Introduce new In Mould Decoration Technology

 

Plan to fix it

  • Develop Organisational Structure, Reporting Lines & Job descriptions

  • Establish departmental procedures & standards for ‘best practice’

  • Recruit a well balanced team of 72 staff including key managers

  • Handle training & career development for senior team members

  • Manage budgets, forecasting, purchasing & stock control activities

  • Control scheduling & production planning, job cards & costings

  • Use RFT for defect analysis & Tops 8D for root cause analysis

  • Ensured efficient deployment of staff to maximise available resources

     

Issues on the way

  • Troublesome supply of soft painted parts to plant.

  • Difficulty transferring Cup holder design to go into a serial production assembly.

 

Result

  •  Transfer complete

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