Sumit Verma

As Deputy Manager at YKK India Pvt. Ltd., I lead production management and engineering operations in the Assembly department, driving Lean implementation, process control, and equipment reliability to maximize productivity across high-volume manufacturing lines. 🔹 Implementing Lean tools (5S, TPM, Kaizen, Poka-Yoke) that boosted productivity by 40% and cut cycle time by 15%. 🔹 Deployed real-time monitoring PDA & POP systems across 150+ machines, significantly reducing downtime. 🔹 Achieved OEE improvement of 16% (2023) and 15% (2022) through targeted process optimization and operational efficiency initiatives. 🔹 Reduced unplanned downtime by 25% through HMI based predictive maintenance and analytics-driven decision-making. 🔹 Executed end-to-end process audits for top-tier clients (Toyota, Reliance, Decathlon), ensuring 100% compliance with quality and operational standards. 🔹 Led optimization programs aligning production and maintenance functions, improving operational efficiency and boosting equipment uptime by 15%. 🔹 Recognized with the Machine Maintenance Expertise Award for managing and optimizing over 100 SPMs and Injection Moulding Machines. 🔹 Honored with the TPM Award (2nd & 3rd position) for spearheading technical and process improvements delivering cost savings exceeding ₹5 million.

As Assistant Manager, I managed daily operations in the Assembly Department and led a team of 100+ members. By applying Lean systems and providing strong technical supervision, I improved efficiency, quality, and cost performance. This experience built the foundation for my current leadership as Deputy Manager. 🔹 Directed Lean workflow optimization initiatives, boosting productivity by 20% and OEE by 15%. 🔹 Reduced waste and improved resource utilization through continuous process improvement initiatives. 🔹 Managed relationships with 8 vendors and 14 suppliers, implementing cost-effective sourcing strategies that reduced expenses. 🔹 Achieved significant cost savings through continuous process improvements and waste reduction initiatives. 🔹 Led internal audits and ensured 100% compliance with ISO standards, strengthening quality assurance and operational reliability. 🔹 Designed training modules to develop strong lean teams, leading to a 25% decrease in errors and an improvement in production quality by 10%.

As Senior Process Engineer, I led process optimization and new production line setups across multiple manufacturing units, integrating TPM, Poka-Yoke, and structured maintenance practices to enhance reliability and minimize downtime. 🔹 Drove process optimization across 12 production lines, streamlining workflows and improving productivity, quality, and resource utilization. 🔹 Implemented Poka-Yoke and TPM strategies, achieving a 25% reduction in defects and a 20% increase in process reliability. 🔹 Led root cause analysis and corrective actions, cutting equipment downtime by 18%. 🔹 Upgraded machine performance through technical enhancements, boosting efficiency by 15% and extending equipment life cycle. 🔹 Partnered with suppliers to ensure 100% on-time material delivery, minimizing downtime and securing uninterrupted production flow. 🔹 Mentored and developed junior engineers, strengthening technical expertise and increasing team efficiency by 15%.

As Process Engineer, I contributed to Lean manufacturing initiatives and maintenance operations, supporting system standardization, cycle time reduction, and the early implementation of TPM and OEE monitoring practices. 🔹 Implemented 5S and Kaizen practices to promote operational consistency, workplace organization, and visual management efficiency. 🔹 Collaborated cross-functionally to minimize cycle times and enhance process reliability. 🔹 Participated in TPM and OEE initiatives, improving visibility into performance metrics. 🔹Supported process documentation and control plan development. 🔹Assisted in machine troubleshooting and technical improvements. 🔹Contributed to vendor coordination and raw material planning. 🔹Played a key role in reducing operational errors and waste.

In my role as a Technical Service Engineer, I handled machine installation, commissioning, and performance validation for clients across North India, ensuring equipment reliability and delivering post-installation technical support. 🔹Installed and commissioned 20+ hot and cold melt machines across North India, enhancing production efficiency and machine uptime. 🔹Delivered technical support and troubleshooting at 30+ client locations, minimizing downtime and ensuring smooth operations. 🔹Customized machine configurations to optimize performance, resulting in improved output quality and operational consistency. 🔹Ensured long-term operational reliability through scheduled service and reporting.

While being employed at Gulati Diesels, I managed DG set installations, preventive maintenance, and electrical panel troubleshooting for commercial clients, ensuring equipment reliability and minimizing downtime. 🔹Led installation and commissioning of 50+ DG sets for commercial clients, ensuring system readiness and customer satisfaction. 🔹Conducted preventive maintenance and root cause analysis at 100+ sites, reducing downtime and improving equipment efficiency. 🔹Strengthened client relationships through responsive on-site support and technical optimization. 🔹 Carried out panel testing, calibration, and system checks to maintain operational stability.