Major Projects

Here are some key projects I've completed.

Project Leader for KVWM (Pridor CD-100 Motorcycle) Development

Atlas Honda Limited

Project Outline and Accomplishments:

1. Optimizing and improving design of 79 parts for cost reduction, customer satisfaction and quality enhancement.

2. Rs. 612 saved per unit motorcycle (cost reduction) by optimizing designs of various parts.

3. Rs. 22, Rs. 33, Rs. 36, Rs. 37, Rs. 5 and Rs. 69 saved per unit motorcycle against “Sleeve RR Wheel”, “Head pipe”, “Stay cover”, “Cowl front”, “Stay winker” and “Side covers” respectively by negotiations with vendors. Overall Rs. 1423 saved per unit motorcycle by price negotiations with respective vendors.

4. Warranty claims reduction from 0.593% to 0.441 % of annual production by improving design of parts. So 34.47% improvement in terms of warranty claims as compared to base model.

5. Direct pass growth from 87.67% to 91.33 % of annual production. So 4.18% improvement in terms of direct pass as compared to base model.

6. Tail light Assembly and Rear Fender Assembly jig design and fabrication in coordination with Assembly plant.

7. Designing and fabrication of “process and inspection fixtures” for stay cover of frame body in coordination with frame body welding plant.

8. Designing and fabrication of “front cowl” and “side covers” painting jigs in coordination with “ABS paint Plant”.

9. Designing and supervising training of all manpower of “Frame body welding plant”, “Frame assembly plant” and “Fuel tank painting plant” for all the design change parts and processes.

10. Successfully conducting and managing all major events (like PP1, PP3 and MP etc) as per guidelines of Honda Motors Japan.

11. Taking counter-measures and closing all product problems (Hinanhyo’s) raised during PP1 & PP3 and getting it approved from Honda Motors Japan.

12. Compiling and finalizing SAP based BOM “Bill of material” in coordination of PPC (Production planning department).

Co-Project Leader for KOKA (CB125F Motorcycle) Development

Atlas Honda Limited

Project Outline and Accomplishments:

1. Optimizing and improving design of 358 parts for cost reduction, customer satisfaction and quality enhancement.

2. 6752 saved per unit motorcycle by price negotiations with respective vendors.

3. Warranty claims reduction from 2.82% to 2.27 % of annual production by improving design of parts. So 24.23% improvement in terms of warranty claims as compared to base model.

4. Direct pass growth from 76.23% to 82.29 % of annual production. So 7.94% improvement in direct pass as compared to base model.

5. Designing and fabrication of “process and inspection fixtures” for all design change parts.

6. Designing and updating Quality management system (operation standards, PQCT’s, MQS, check-sheets etc.) of all in-house departments as well as all vendors, in coordination with respective departmental managers.

7. Designing and supervising training of all manpower of for all the design change parts and processes.

8. Successfully conducting and managing all major events (like PP1, PP2, PP3 and MP etc) as per guidelines of Honda Motors Japan.

9. Taking counter-measures and closing all product problems (Hinanhyo’s) raised during PP1, PP2 & PP3 and getting it approved from Honda Motors Japan.

10. Compiling and finalizing SAP based BOM “Bill of material” in coordination of PPC (Production planning department).

Project Leader of “1 Million to 1.25 Million Annual Plant Capacity Expansion Project” with budget of Rs. One Billion

Atlas Honda Limited

Project Outline and Accomplishments:

1. Project Outline and Accomplishments:

2. Rs. 43.57 million saved as result of negotiations with maker & implementation of “early equipment maintenance” (TPM).

3. Rs. 11.23 million saved as result of FOG (Lean manufacturing).

4. Rs. 25, 11 and 14 saved as per crank shaft, cylinder head and crank case set respectively by achieving economies of scale.

5. Successfully shifted 86 Machines with an average weight of 6 Tons to sister’s company and their re-installation along with their “Quality assurance confirmation” with no delay in production.

6. Successfully planned (with suppliers for raw material) and built OIKOMI (safety stock) for machine’s transfer.