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Manjit Pophali

Manjit Pophali

Pimpri, Maharashtra
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About Manjit Pophali:

Seasoned and dynamic professional with 23+ years of diverse experience in Production Planning & Control,  Material Planning, Inventory Management, KANBAN, Internal Supply Chain Management, Spare Parts planning, CNC Machining (Production & Quality), Fabrication & Mechanical Maintenance, Mission Gemba, TQM and Software Programming. Professional record demonstrates successful association with organizations in India as well as in Middle East. Highly skilled in MS Excel programming with excel VBA for efficient MIS reports generation at a click. Proficient in Arduino Uno microcontroller programming & interfacing it with Excel VBA programming. Proficient in SAP PP module.

I am presently working as Head PPC in Tata Advanced Systems Ltd. Nagpur, India. 

Looking forward for growth & further experience. 

Experience

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TATA Advanced Systems Ltd., MIHAN SEZ Nagpur           Aug 2016 to till date


HOD - Production Planning & Control                                                 Sr. Manager PPC

 

  1. Managing 4 customers Boeing, Avcorp, RUAG, Rolls Royce with a team of 20 executives in PPC.
  2. Co-ordination with Program Management for getting the customer demand for ACFB (Advanced Composite Floor Beam) of Boeing project, Rod assemblies of Avcorp project, RUAG detailed parts (both machining & sheet metal parts) and Rolls Royce detail parts.
  3. Preparation of weekly Build plan for a horizon of 18 months including any Emergent demand of customer from time to time. Uploading this 18 months week wise plan in SAP with MD61 T-code for MRP.
  4. Ensuring the preparation of date wise plan for shop floor scheduling with constraints of Layup Mandrel on Composite side and Machine & Fixture constraints on Metallic machining side.
  5. Use of APS (Advanced Planning & Scheduling) Software Siemens Opcentre for daily scheduling of work orders with flag rush indicator where ever applicable.
  6. Monitoring the plan vs actual as per daily plan in PPC Gemba slides & driving the complete plant team through Gemba to achieve on-time delivery.
  7. Plan & ensure the FG & WIP+SFG inventory within norms.
  8. Raw material planning with lead times of Titanium as high as 64 weeks, Bought Out Items planning, Consumables & cutting tools planning. Ensuring schedules to SCM through SAP. 
  9. Ensuring up-keep of department related AQMS i.e. AS 9100 D and EHS documents & records.

 

Selected Achievements

 

  1. “Pick-by-light” system: Voluntarily took the initiative in designing the architecture, physically making the circuit & then Arduino programming & interfacing with Excel VBA for “Fasteners Visual Management System” by automatic LED glowing & small sticker printout simultaneously thereby ensuring poka-yoke while kits preparation; a pick-by-light system. Patent application for the project is in process.
  2. Second project with Arduino is done for alerting the CMM operator 10 min. before the CMM machine stops triggering him to complete all required tasks so that machine can run continuously thereby saving idle time of 6-8 min. in each cycle. This is done by automatically sounding the buzzer 10 times coupled with LED blinking for 10 min.
  3. Third project with Arduino is done for priority work order for Tankline. The user scans the bar code on work order and respective colored LED glows at once as per priority of that order. i.e. Red color LED for 1st priority, yellow color LED for 2nd priority & blue color for 3rd priority.
  4. Aerospace Quality Management System-AQMS AS9001 Rev. ‘D’ Internal Auditor.
  5. Taken initiative and drove the team for automatic raw material planning & consumables planning thru SAP MRP.
  6. Efficient MIS reporting to Sr. Management & Customers; received appreciation & honors from Boeing for referring the daily MIS as “Manjit’s Report”.
  7. Time saving projects for sub-ordinates in day to day reports generation thru expert excel VBA programming. Example: Automatic priority generation & e-mails at a click thru MS Excel in predefined format to shop floor.
  8. Quarterly physical Inventory reconciliation against SAP; accuracy 100% wrt WIP till now.
  9. Represented TAL Nagpur in PPC Process Council during integration of various companies of TATA group and framed the final process & SOPs of PPC for new company, TATA Aerospace & Defence Ltd.
  10. Helping other departments by doing Kaizens with Arduino microcontroller & Nodemcu based visual management projects and also automatic excel VBA programs.
  11. Led in developing 60+ Tableau reports for management reviews. 

 

Ashok Leyland Ltd., Bhandara       Jan 2006 to Jan 2010 & May 2010 to Aug 2016


Manager - Production Planning & Control

  1. Date wise planning for all varieties of Gears, Casings & Synchro Rings used in the assembly of Gear Boxes and monitoring the plan vs actual highlighting the short/excess to Management.
  2. Managing the complete supply chain of machine shop from issuing the raw material to processing, material handling, giving pick lists and managing the dispatches to customers. 
  3. Complete co-ordination with out-sourced Tonglit Logistics for dispatch of spare parts to SPD & other Ashok Leyland Units through proper packing & dispatch process.
  4. Daily Management of all KPIs and parts inventory for ensuring its optimum level thus meeting customer demand on time. 
  5. Complete documents preparation & audit facing for ISO TS 16949.
  6. Functional consultant for Ashok Leyland indigenously developed ERP & SAP System.
  7. Skillfully sort out SAP related issues of Production and generating Production Orders & Issue Lists in the same.
  8. Supervising Inventory Control and apprising the top management about the quarantine / sidetracked material lying on shop floor.
  9. Decision making in M/cs loading, in case of changed requirements of GBs and Pantnagar & Ennore Units’ parts requirements.
  10. Input-Output Reconciliation (IOR) of material and quarterly physical verification of WIP and complete stores stock and compile it against SAP stock for accurate operating inventory information.

Selected Achievements

 

  1. Successfully guided the company in a team of 8 members for pocketing the most coveted India Manufacturing Excellence Award 2007 (IMEA 2007) in ‘Platinum’ category which was broadcasted on NDTV profit channel.
  2. Designed & developed in MS Excel the completely automatic solution for no. of sets cleared of Gear Boxes (as per BOM) after dispatch of parts from Bhandara to Pantnagar. PNR can also see the sets cleared as per the Lorries received at their end just by clicking the lorry no. This project got special appreciation from Vice President Pantnagar.
  3. Designed & developed in MS Excel VB, the complete automatic date wise components’ planning software which big shot companies HP, Oracle and SAP couldn’t provide.
  4. Presented the above 2 projects in company’s 18th Mini Improve competition.  
  5. Actively involved as a Team Member for CII EXIM Bank Award for Manufacturing category. 
  6. Developed the SAP Monitoring System in co-ordination with Systems Department tracking quantity of material sent to Heat Treatment & the material received from HT thereby facilitating the Management to see online status regarding the production rate at each stage.
  7. Associated as the Leading Team Member of the team working for Rajiv Gandhi National Quality Award 2008. 
  8. Designed & developed 30 different projects in MS Excel VBA for easy & instant MIS reporting for right from Gate Security to OEE/OLE calculations in Maintenance; Auto reminder mails thru Excel on every specific date of the month.

 

Heavy Vehicles Transmissions Ltd.

A subsidiary of Tata Motors, Jamshedpur                                 Jan 2010 to May 2010


Manager - Production Planning & Control

  • Working out total Spare Parts (Gears, Shafts, etc.) requirement of Spare Parts Department and supplying as per monthly requirement by managing the complete supply chain right from procuring the raw material to dispatch.
  • Daily planning of gear boxes to be assembled in line with vehicles to be produced daily.
  • Daily planning of spare part components required for the gear boxes & SPD.
  • Daily packing, invoicing and dispatching of gear boxes & spare parts to all customers.
  • Managing total logistics related activities viz. coordinating with customers for their hour based need of gear boxes & co-coordinating with transport for timely delivery of gear boxes
  • Managing total logistics related to spare parts dispatch viz. coordinating with various spare parts dept. at various locations in India and ensuring timely invoicing, packing & dispatch to all.

 

Bajaj Steel Industries Ltd. (CNC Machining Div.)  

Jul 2001 – Oct 2002 & Mar 2004 – Dec 2005


Senior Engineer – Production & Quality, Mar 2004 – Dec 2005

Production & Development Engineer, Jul 2001 – Oct 2002

 

  1. Actively involved in CNC Programming on Fanuc & Sinumerik controls and setting up the machines for mass production.
  2. Carried out Maintenance Activities including
  3. Erection and commissioning of Turning Centers of FEELER-TAIWAN including FTC -20, FTC-30 with FANUC Control
  4. Vertical Machining Centers, VMCs of FEELER-TAIWAN with SIEMENS Control and conventional machines like Center Lathes, Radial Drilling m/c.
  5. Single Acting, Single Stage Air Compressors of Ingersoll-Rand.
  6. Daily, Weekly, Monthly Maintenance of FTCs & VMCs. 
  7. Ensured strict Quality Control – In-process and final inspection of machined components with accuracies up to 10 microns.

 

Bahrain Bulk Trade WLL, Fujairah Branch, UAE                        Oct 2002 – Sep 2003

 

Mechanical Maintenance In-charge

 

  1. Involved in executing maintenance of 
  2. Primary Jaw Crusher, Vibrating Feeder, Vibrating Screen, Discharge Conveyor & Dust Conveyor
  3. Goodwin Barsbay, Impact Crushers 2 nos. of capacity 250 TPH each.
  4. Hazemag APK 108’ Impact Crusher including its Hydraulic System.
  5. Discharge & Feed Roller Conveyors (12 nos.) from Primary Crusher to finished 10 mm, 20 mm, & 0-5 mm aggregate. 

 

Aarya.Com Pvt. Ltd.                                                               Oct 1999 – May 2001

 

Web Developer

 

  1. Developed Websites & Ecommerce Projects in ASP, HTML, SQL Server 7.0, and MS-Access. 
  2. bsjshau.com
  3. nagpuronnet.com
  4. ciims.com
  5. hedgewarraktapedhi.com
  6. mba-ambedkar.com
  7. nagpurpyrolusite.com
  8. Developed projects on IBM AS/400 platform for the clients in Singapore - Websites & Ecommerce Projects in ASP, HTML, SQL Server 7.0, and MS- Access.
  9. Supervised development projects for Nagpur (India) Clients.

 

Pix Transmissions Ltd., Bazargaon                                           Jul 1998 – Sep 1999


Maintenance Engineer

 

  1. Managed the entire Engineering Workshop with Lathes, Milling M/c, Surface Grinder, Cylindrical Grinder, and Plano milling M/c.
  2. Handled fabrication of machines used for manufacturing, processing and cutting of ‘V’ belts.
  3. Supervised Erection, Commissioning & Maintenance of Conventional Machines like Center Lathes, Vertical Milling M/c, Surface Grinder, Cylindrical Grinder, and Plano Miller; planning & development of fixtures maintenance of Cooling Tower, Air Compressors, ‘V’ Belt Cutting machines, Hot Pots used for curing the sleeves of ‘V’ belts, Electrically & Pneumatically operated Drum Building m/c, Band Saw Cutting M/c.

 

Selected Achievements

  1. Received special appreciation letter for increasing the production of Building Drums used for manufacturing of ‘V’ belts, by 300% in day by designing and fabricating a fixture.

Education

B. E. Mechanical

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