Sandesh Mallur

Industrial/Manufacturing Engineering and Tooling Manager

• Job Details:Engage in feasibility analysis, tooling development, and CAPEX planning for build-to-print (BTP) and global transfer projects. Review and validate special processes and prepare industrial readiness guidelines to improve operational planning. Augment productivity and resource utilization through strategic layout design, manpower allocation, and MAE planning. Drive productivity improvement through the development of customized tooling and robust manufacturing processes. Implement line balancing, capacity planning, and OEE (Overall Equipment Efficiency) enhancement initiatives to optimize resources (men, materials, machines, and methods). Employ lean concepts such as supermarket systems, quick changeovers, and takt-based workflow to streamline production flow. Reduce defect rates through poka yoke, preventive measures, and continuous improvement programs.

Industrial Engineering and Maintenance Manager

• Job Details:Decreased tool changeover time and improved stamping cycle time by implementing cluster tools and organizing a tool crib system. Maximized shop floor productivity by installing air-cooling systems and reducing fatigue during peak operations. Designed and deployed BET inline welding fixtures, achieved consistent production accuracy and minimized frame warping. Ensured high machine availability (>97%) through systematic preventive maintenance (PM) with actual adherence exceeding 90%. Monitored and improved MTTR (Mean Time to Repair) and MTBF (Mean Time Between Failure) to boost equipment reliability. Maintained maintenance budgets in line with organizational targets while ensuring timely calibration of equipment and pressure vessels. Oversaw utility maintenance, covering STP, ETP, DM/RO plants, compressors, PNG, cryogenic liquid N₂ systems, HT & LT yards, pallet trolleys, forklifts, scissor lifts, jib cranes, and related infrastructure. Contributed to overall ROI gains by initiating energy and process efficiency projects.

Assistant Manager (Tool Room Production) / Project Coordinator

• Job Details:Managed tool room operations for common rail pump (CBX) housing manufacturing with high process reliability. Oversaw tool room production activities, including manufacturing of checking and attribute gauges such as snap, ring, plug, thread plug, and thread ring gauges. Developed and standardized workstations, reduced lead time and enhanced throughput. Conducted time studies, implemented measurement system analysis (MSA) improvements, and led capability studies (CM/CMK). Collaborated with production, planning, and quality teams to resolve operational issues and support deviation management (CAPA). Orchestrated lean initiatives including poka yoke, 5S, red table meetings, and total productive maintenance (TPM) to drive quality improvements and boost overall equipment effectiveness. Localized and developed tooling and gauges for key clients such as Hero Honda, Honda Motorcycle, Tata, and Renault.