Prabhakar Bulbule
Hutchinson | Ex-Freudenberg | ASQ Six Sigma Green Belt | Industrial Engineering Expert (Operations). Contact: +91-8054967685
- Role
- Production Manager at Hutchinson
- Location
- Chennai, TN, IN
- LinkedIn followers
- 500 followers
About Prabhakar Bulbule
Highly dedicated and results‑oriented Production Manager with 12 years of experience in high‑volume manufacturing, leading end‑to‑end Value Stream operations, production planning, quality control, and cost optimization. Proven success in improving OEE, COPQ, scrap, and strengthening SQDCP & HES performance through Lean, Kaizen, TPM, 5S, SPC, QRQC, LPMS and 8D problem‑solving. Key User skills in SAP & ERP Silver PP module, demand and capacity planning, manpower deployment and cross‑functional alignment with SCM team to ensure smooth material flow and on‑time production. Known for developing high‑performance teams, driving continuous improvement, and ensuring strong compliance with IATF16949, ISO systems, safety systems, and customer requirements to consistently deliver operational excellence.
Experience
Production Manager
May 2022 — Present · IN
I lead the seamless transfer and optimization of manufacturing operations from LJF France to Hutchinson India, ensuring full alignment with Hutchinson’s Global One‑Plant Concept. By standardizing processes, strengthening operational excellence, and driving cross‑site collaboration, I am fully accountable for establishing and advancing O‑rings manufacturing in India. My focus is on building a world‑class operation that mirrors global benchmarks while enabling sustainable growth and high‑performance manufacturing.Responsibilities:Demonstrated a strong safety‑driven leadership mindset by achieving accident‑free days since the start of production in India, maintaining 0 TRIR and 0 First‑Aid cases through rigorous safety systems like DS reporting and proactive risk mitigation with HIRA.Led the operations team to consistently maintain 0 PPM (zero defects) and 0 warranty claims from the start of operations, demonstrating strong process control, robust quality systems, and exceptional customer satisfaction.Managed high‑volume production of 8 million+ parts/month across Automotive Application parts.Led a team of 58 Operators, 3 Shift Engineers and 1 Industrial Engineer with polyvalent skills development. Implemented DOJO Training center & Digitalized Skill Evaluation.Improved OEE from 76% to 83% by optimizing molding, post‑curing and deflashing.Reduced scrap from 3.2% to 1.4% and COPQ from 3.6% to 1.8% through SPC, Poka‑Yoke QRQC & structured RCA/8D.Skilled in demand forecasting & capacity planning, manpower deployment and MRP‑driven production scheduling on regular basis.ERP Silver & SAP PP Key User: Managed MRP runs, BOM/Routing updates, Work Center planning and daily plan conversions.Implemented Lean, Kaizen & TPM initiatives improving line stability and productivity.Continuous Improvement: Continuously monitoring and optimizing the localized processes, implementing best practices to enhance efficiency and overall production performance.
Education
SVKM's Narsee Monjee Institute of Management Studies (NMIMS)
Diploma, Post Bachelors Diploma in Supply Chain Management
2019 — 2019
JSS Banashankari Arts,Commerce & S.K.Gubbi Science College, Vidyagiri Dharwad
12th Standard, Science
2008 — 2010
National Institute of Technology Karnataka
Bachelor of Technology (B.Tech.), Mechanical Engineering
2010 — 2014
Karnataka High School Dharwad, Karnataka
10th Standard
2007 — 2008
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