Sameer Phatak — Head of Manufacturing Engineering
Pune, Maharashtra
Manufacturing engineering leader with seventeen years in forging, machining and assembly for commercial vehicles, the last five running engineering across three plants. Delivered a ₹42 crore capacity expansion that lifted output 38% without new floor space, and took group conversion cost down 14% over three years. Leads a department of 46 engineers and technicians.
Experience
Head of Manufacturing Engineering, Prashti Mobility Systems · August 2021 – present
Engineering across three plants: 46 engineers and technicians, ₹60 crore annual capital plan.
- Delivered a ₹42 crore capacity expansion that raised output 38% on the existing footprint, commissioned six weeks ahead of the customer start-of-production date.
- Took group conversion cost down 14% over three years through line rebalancing, automated gauging and a supplier tooling consolidation.
- Lifted overall equipment effectiveness across 11 machining cells from 58% to 79% by making TPM a line-owner responsibility rather than a maintenance one.
- Built a machine-data platform covering 140 assets that cut unplanned downtime 31% in its first year.
- Hired and developed 18 engineers, five of whom now run their own cells; department attrition fell from 24% to 9%.
Manager — Manufacturing Engineering, Nirvaan Forgings · May 2016 – July 2021
- Led the move from three-shift manual forging to two automated lines, raising tonnes per operator-hour by 2.6 times.
- Reduced die cost per tonne 27% by bringing die design in-house and standardising on four preform geometries.
- Commissioned 14 machines and two robot cells against a ₹31 crore budget, all inside approved capital.
Assistant Manager — Production Engineering, Tanvish Engineering Works · June 2012 – April 2016
- Relaid a gear-machining shop around cellular flow, cutting work-in-progress 44% and part travel by 380 metres.
- Raised first-pass yield on a hobbing line from 86% to 97% by changing over on tool life rather than shift end.
Production Engineer, Tarangi Gears · July 2009 – May 2012
Joined as a graduate engineer trainee.
- Ran a 22-machine turning section and lifted schedule adherence from 81% to 96%.
- Cut coolant consumption 40% through concentration monitoring, saving ₹11 lakh a year.
Education
- Executive MBA Operations Management · S.P. Jain Institute of Management and Research · June 2017 – May 2019
- B.E. Production Engineering · Veermata Jijabai Technological Institute (VJTI) · August 2005 – May 2009
Skills
- Manufacturing: Line design and balancing, Forging and machining processes, Robot cell integration, Tooling strategy, Capacity planning
- Operating system: TPM, Value-stream mapping, Six Sigma, Kaizen, Standard work, SMED
- Leadership: Capital planning, Supplier development, Team building, Customer SOP readiness, Conversion cost ownership
- Digital: MES and machine data, Power BI, SAP PP/PM, Condition monitoring
Certifications
- Certified Maintenance & Reliability Professional (CMRP) — Society for Maintenance & Reliability Professionals
- Lean Six Sigma Black Belt — American Society for Quality
- TPM Instructor Course — Japan Institute of Plant Maintenance