Paulcy Mathew
Summary
Result-driven Production Engineer with a proven track record of optimizing manufacturing processes and ensuring top-quality output in the automotive industry. Adept at leading cross-functional teams, implementing continuous improvement initiatives, and enhancing production efficiency. Seeking opportunities in Canada to leverage my skills and expertise in a progressive and innovative work environment.
Over 9 years of experience in Production Engineering with expertise in process optimization, quality assurance, and Lean principles implementation in high pressure die casting. Proven ability to lead and manage cross-functional teams of 35+ employees to achieve operational excellence. Skilled in production planning, workflow development, troubleshooting, root cause analysis and quality control. Proficient in Microsoft Office, process control, die design, PPAP auditing, and casting rejection control. Committed to continuous improvement and safety environment enforcement.
Overview
11
11
years of professional experience
Work History
Assistant Manager Production
Dolphin Die Cast Private Limited
06.2023 - 09.2023
- Developed and implemented key performance indicators (KPIs) to measure and improve production efficiency, quality, and safety
- Collaborated with the R&D team to introduce advanced technologies, resulting in increased productivity and product quality
- Conducted regular safety audits, ensuring zero accidents over the past year
- Initiated cross-training programs to enhance team skills and reduce downtime during peak production periods
- Optimized the supply chain through strong vendor relationships, reducing material lead times and improving production schedules
- Acted as a liaison between the production team and upper management, providing regular reports on production metrics and improvement initiatives
- Managed the departmental budget, optimizing resource allocation and reducing operational costs by 10% while maintaining or improving production output
- Instituted an employee recognition program, resulting in a 20% reduction in turnover
- Developed and implemented a preventive maintenance schedule, reducing unplanned downtime by 15%.
New Product Development Engineer
Enkey Engineering Works
05.2022 - 06.2023
- Spearheaded design improvements in dies to maintain casting rejection rates below 2% while meeting customer requirements
- Collaborated closely with suppliers and customers to ensure precise die manufacturing aligned with specifications
- Played a pivotal role in liaising with customers throughout the die approval process, addressing feedback promptly
- Orchestrated and coordinated trials, pilot lot casting production, and quality testing, ensuring compliance with strict quality standards
- Conducted thorough PPAP (Production Part Approval Process) audits to meet stringent quality control demands
- Worked closely with die manufacturers to facilitate the efficient design and production of dies while adhering to project timelines.
Production Engineer
Enkey Engineering Works
09.2018 - 05.2022
- Led a team in consistently achieving and exceeding production targets on time, resulting in improved company performance
- Implemented Lean principles, optimizing workflow and significantly enhancing product quality
- Conducted comprehensive analysis of quality issues, swiftly troubleshooting and implementing effective corrective actions
- Managed a diverse workforce, allocating resources efficiently to maximize productivity
- Spearheaded continuous improvement initiatives, boosting overall productivity and reducing production costs
- Implemented and evaluated the effectiveness of 5S principles, enhancing workplace organization and efficiency
- Provided comprehensive training programs for operators, helpers, line inspectors, and supervisors, contributing to a highly skilled and motivated team
- Successfully controlled rejection rates of castings, ensuring high-quality end products
- Investigated root causes of failures and recommended design, tolerance, and process changes, improving product manufacturability and performance
- Conducted in-depth root cause analyses and executed corrective actions, minimizing defects and enhancing overall product quality
- Collaborated effectively with cross-functional teams, optimizing processes and boosting overall performance
- Achieved a remarkable 3% increase in productivity by developing and implementing innovative production processes for both new and existing products.
Die Maintenance Engineer
Enkey Engineering Works
12.2017 - 09.2018
- Maintained readiness of dies for production
- Managed spare parts inventory
- Reduced die breakdowns through effective corrective actions
- Scheduled dies for service based on production priorities
- Implemented die corrections to reduce fettling time
- Handled requisitions for replacement tools
- Conducted day-to-day duties accurately and efficiently.
Production Engineer
Modern Metals And Trading Est
07.2016 - 10.2017
- Ensured timely project completion
- Oversaw the production team
- Provided training to workers
- Prepared engineering documentation for manufacturing processes, equipment specifications, and change notices
- Supervised the entire production process and prepared proper documentation for dispatch.
Production Supervisor
Enkey Engineering Works
03.2013 - 04.2016
- Achieved production targets on time
- Conducted quality problem analysis and troubleshooting
- Implemented process control and documented processes
- Controlled rejection rates of castings
- Implemented 5S principles.
Education
B. Tech in Mechanical Engineering -
Bharath Institute of Science And Technology
Chennai, India06.2012
Skills
- Die Design and Manufacturing Knowledge
- Process Optimization
- PPAP Auditing
- Lean Principles Implementation
- Team Leadership (35 employees)
- Production Planning
- Root Cause Analysis and Corrective Actions
- Workflow Development
- Product Design for Manufacturability
- Troubleshooting and Root Cause Analysis
- Continuous Improvement Initiatives
- Innovative Production Process Development
- Engineering Documentation Creation
- Microsoft Office Proficiency
- ERP Proficiency
- Process Control and Documentation
- Quality Control
- Equipment Monitoring
- Inventory Coordination
- Production Management
- Problem Solving
Languages
English
Full Professional
Tamil
Professional Working
Hindi
Limited Working
Malayalam
Native or Bilingual
Timeline
Assistant Manager Production
Dolphin Die Cast Private Limited
06.2023 - 09.2023
New Product Development Engineer
Enkey Engineering Works
05.2022 - 06.2023
Production Engineer
Enkey Engineering Works
09.2018 - 05.2022
Die Maintenance Engineer
Enkey Engineering Works
12.2017 - 09.2018
Production Engineer
Modern Metals And Trading Est
07.2016 - 10.2017
Production Supervisor
Enkey Engineering Works
03.2013 - 04.2016
B. Tech in Mechanical Engineering -
Bharath Institute of Science And Technology
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