Bharath Kumar

About Bharath Kumar

Planned production using the MES system (MRP-based), achieving 99.9% on-time …

Experience

1. Production Engineer

   Magna Automotive India Private Ltd

   Oct 2020 — Present · Chennai, IN

   Planned production using the MES system (MRP-based), achieving 99.9% on-time delivery. Maintained a safe work environment, meeting the zero-accident target. Motivated operators through Kaizen, SMED, 5S, TPM, and suggestion programs. Improved labor efficiency with better production planning. Increased PPH (Parts per Person per Hour) to boost productivity. Led SMED projects to fix bottlenecks in key production lines. Completed Kaizen projects on time to improve processes. Developed strategies to meet the 85% OEE target. Improved efficiency and reduced costs through lean manufacturing. Reduced product risks by addressing high-risk FMEA items. Led Kaizen and benchmarking activities to optimize shop floor work. Created and updated standard operating procedures for production. Led the implementation of Magna Factory Concept (MAFACT) in manufacturing. Reviewed production data with the Production Head for better planning. Worked with cross-functional teams to allocate resources efficiently. Managed inventory levels to maintain optimal stock and prevent overstocking or understocking. Assigned and supervised workers to meet daily production targets and handle 4M changes. Supervised 800 employees at all production stages. Acted as a bridge between workers and management, ensuring concerns were resolvedLed prototype build launch planning, achieving 100% attainment. Assessed product and process feasibility through Launch Readiness Reviews with crossfunctional teams. Developed PFD, PFMEA, and SOPs for new projects in collaboration with cross-functional teams. Designed assembly lines with Poka-Yoke controls to prevent mix-ups, missing components, incorrect assembly, and inspection errors. Implemented Continuous Risk Reduction (CRR) initiatives to minimize high-risk FMEA items for individual products.