Routhu Rakesh
Miyapur
Summary
Highly experienced Assistant Manager with 12+ years of expertise in Aero structures Assembly Manufacturing, delivering top-notch results on reputed projects like Sikorsky S-92, Chinook CH-47, Pilatus PC-12, and Airbus C-295. Proven track record in Lean manufacturing, assembly production, new product development, and aerospace fabrication processes. Skilled in training and skill development, risk management, internal audits, and cost analysis. Successfully delivered 150 S-92 Fuselage ship-sets, 200th ship-sets of Chinook with zero defects on time, and 175th ship-sets of PC-12 fuselage assemblies.
Overview
13
13
years of professional experience
Work History
Assistant Manager
Tata Advanced Systems Limited
01.2012 - Current
- Assembly / Manufacturing – Aero structures
- Sikorsky S-92, Boeing Chinook CH-47, Pilatus PC-12, AIRBUS C-295
Assistant Manager Production & Manufacturing Engineering
Tata Advanced Systems Limited AIRBUS C-295
04.2023 - Current
- Leading Airbus C295-MCA (A versatile military transport aircraft) Aircraft Assembly Project
- Leading as Production & Manufacturing assembly department as end to end responsibility of MCA Assembly function
- Leading the Operational activities to align all departments stakeholders with taking decisions towards achieving the target and safe work
- Drive, with Airbus team on Plan, Progress and challenges
- Align to all Operational departments accordingly on delivery
- Managing start of the production assembly line of C-295 aircraft
- Responsible for coordinating and managing all aspects of aircraft production
- Plan, organize, and supervise production schedules, ensuring that aircraft are manufactured according to specifications, quality standards as per AIRBUS regulatory requirements
- Closely operating with engineering teams, deliver chain management, and nice manage to optimize manufacturing approaches and meet manufacturing start dates
- Responsible & coordinating for the qualification of the special process and personal certifications requirements from the AIRBUS team
- Finalization of the CAPEX & OPEX budgets for the Pneumatic hand tools & cutting tools for the start of production
- Training all the team members on the stringent requirements on the AIRBUS specifications & manufacturing processes adhere to CASA standards
- Motivating and guiding teams, resolving conflicts, and fostering a positive work environment to achieve production goals efficiently
- Closely working with the AIRBUS team for the resolving engineering issues which where found out during the production
- Motivating and guiding teams, resolving conflicts, and fostering a positive work environment to achieve production goals efficiently
- Responsible for planning, development and execution of production operational strategies for meeting on time delivery commitments to the customers
- Closely working with the AIRBUS team for the resolving of the engineering issues which where found out during the production
- Driving safety, EHS across the organization in all functions
Assistant Manager Production & Manufacturing Engineering
Tata Advanced Systems Limited Boeing CH-47 & Pilatus PC-12
04.2022 - 03.2023
- Oversaw the Assembly line of Boeing CH-47 Crown, Tail-cone and Pilatus PC-12 aircraft
- Role interacts with other department’s viz
- QA, ME, SCM, PPC and others on a daily basis involving routine work in a clear and effective manner to ensure production line does not stop
- Operation Analysis: Formulated integrating plans of all projects CAPEX based on consumption trends by optimizing common tools across projects to common set of supplier and achieve balance between performance and cost effectiveness
- Resource Analysis: Resource management (manpower and machines), devising mobilization strategies (actual vs requirement) for cost optimization
- Productivity Analysis: Analyzed all the resources and comparing the total work done with the current/ available resources with Job cost report monthly for monitoring
- Manufacturing Engineering: Creating build plans with work instructions to assist assembly team to perform tasks, provide disposition as per OEM specifications for any reject parts for rework, authorize FAI/DFAI for inspection of products, creating COS for the supplier to produce parts as per engineering requirements, perform process improvement activities like APQP & PFMEA and monitor changes in engineering/ configurations from OEM and flow down instructions in documents to shop to build, after analysis of change through CIB
- Working on Bill of material, EBOM & MBOM Creation, Purchase request in SAP HANA, SAP PEO
Senior Production Support Engineer
Tata Advanced Systems Limited Boeing CH-47 & Pilatus PC-12.
04.2020 - 03.2022
- Oversaw the assembly line of Boeing CH-47 Crown & Tail-cone and Pilatus PC-12 aircraft Sub-assemblies
- Responsible for processing schedule, Production order, inventory accuracy and requirement, work procedure and duty requirement, considering budgetary limitation and time constraint
- Enhanced employee management by developing schedules, tracking time and administering payroll
- Monitored employee productivity and optimized procedures to reduce costs
- Responsible for handling Customer queries on assembly line production
- Responsibility for checking of sustenance of lean manufacturing procedures
- Management Representative for all audits related to regulatory, Safety and customer process oriented in floor
Production Engineer
Tata Advanced Systems Limited Boeing CH-47
04.2015 - 03.2020
- Manufacturing of Aero structure Assemblies of Tail Cone and Crown for Boeing Chinook-47
- Establish assembly line of Chinook CH-47 Tail-cone and Crown
- Responsible for leading a team to assemble the detail parts to Sub-assembly and Sub-assembly to panel for CHINOOK-47 Defense Helicopters
- Worked with a variety of assembly tools and test equipment
- Participated and/or led Kaizen events
- Performed Lean manufacturing process
- Improved work cell setups with upgraded tooling and manufacturing aids
- Scheduled all WIP jobs and followed them through completion
- Worked together with supporting departments and Engineering during qualification and acceptance testing of new products
- Modify Production processes to improve On-Time Delivery
- Responsible for Improvement of productivity by decreasing NVA in assembly
- Adherence of Takt time by frequent monitoring on status
- Responsible to check skill gap and training as per requirement
- Performed Audit preparation like AS9100, EHS, OSHA etc
- Performed Root Cause Analysis on defects and recommending process adjustment to eliminating them
- Annual Budget forecasting for assembly line
Production Jr. Engineer
Tata Advanced Systems Limited Sikorsky S-92
01.2012 - 03.2015
- Manufacturing of Aero structure Assemblies of center fuselage for Sikorsky S-92 Helicopter
- Responsible for leading a team to assemble the cabin of the Sikorsky S-92 helicopter
- Responsibilities include studying the drawings, preparation of product structure, identify fabrication parts, bought out items (BOI), tools required to perform the assembly operation
- Planning and sequencing of operations to be done at various stages viz., sub assembly stage, main coupling jig and off jig stage which comprises of both sheet metal and composite parts
- Preparation of Master process sheets and Technical Instruction sheets for sub-assemblies and assemblies
- Worked on aero structure & harness installation of Sikorsky S-92 helicopters
- Knowledge on routing of harness, installation of clamp, Crimping and testing of harness, Soldering on harness
- Applied excellent problem-solving, process development and strategic implementation skills to lead and support all areas of operations
- Built and strengthened relationships across functional leadership areas to keep revenue development and operational plans interconnected and effective
- Responsible for Manpower management across shop floor
- Creating SOP's, HWI's and OI's for assembly process
- Complete adherence on Jig level takt time in shop floor
- Maintaining 5’s, TPM, across assembly line
- Resolving technical issues on aero structure
- Knowledge on drilling, Riveting, Cold working, Nut plate installation, Bush installation, Performed hydraulic test, Rain water Test, Bush Installation
- Ensuring on "Clean as you go", Proper 5's, TPM, Proper usage of PPE's and other safety equipment’s
- Usage of Proper tools as per job card given
- Worked directly with QA personnel to identify and correct defects
Education
B.SC AME - Aircraft Maintenance
Singhania University, Rajasthan
Aircraft Maintenance Engineering - Aircraft Maintenance Engineering
Sigma Aviation Academy, Hyderabad
Intermediate -
Guntur vikas junior College, Hyderabad
Class X -
Vignan vidyalayam, Hyderabad
Skills
- Aero structures Assembly Manufacturing
- Lean manufacturing
- New product development
- Aerospace fabrication & Assembly processes
- Training and skill development
- Risk management
- Internal audits
- FMEA & PFMEA
- Employee Performance Evaluations
- Operations Management
- Cost Reduction analysis
- Recruiting and interviewing
- Employee performance evaluation
- Business development understanding
- Budgeting and finance
- Staff Training and Development
- Honeycomb structure
- Assembly production and process
- Aerospace painting and coating process
- Aerospace fabrication process
- Workload Management
- Staff Supervision
Accomplishments
- Successful delivered 200th ship-sets of Tail Cone and Crown for Boeing CH-47 Chinook Helicopters
- Successful delivered 175th ship-sets of Pilatus PC-12 Fuselage assembly
- Delivering ship-sets with zero defect
- Received Supplier Inspection Delegation (SID) program for Boeing BDS
- Hands on experience on Power feed guns, Cold working special process and Engine mount drilling
- Trained at BOEING Helicopters, Macon, USA for Aero-structures Assembly, Fabrication and Installation during Sep2015-Oct2015
- Produced 150 ship-sets Fuselage cabins of Sikorsky S-92 at best quality rate and on time delivery record
- Awarded with Best Improvement/Supporting Award for on-time deliveries
- Reduced number of Non-conformances to ≤1 by process optimization
Careerconspectus
Jan-2012 to Present, Tata Advanced Systems Limited
Areas Of Excellence
- Lean Manufacturing
- Honeycomb structure
- Assembly Production and Process
- Aerospace painting & Coating Process
- Aerospace Fabrication Process
- Why-Why, Fishbone analysis
- 5’S, Kaizen and other Shop floor practices
- Skill Development
- Aero structure Assembly
- SAP
- Microsoft Office, Excel, PowerPoint
- FMEA, PFMEA
- Training and Mentoring
- Cost analysis and savings
- Product development
- Internal Auditor for EHS, AS9100D
- On Time Delivery reliability
- Risk Management
Personal Information
- Father's Name: R. Venkateswara Rao
- Date of Birth: 03/19/91
- Nationality: Indian
Languages
English, Hindi and Telugu
Disclaimer
I hereby declare that the above furnished details are true to the best of my knowledge. If given an opportunity further undertake to uphold the fair name of the concern by maintaining high standards of integrity and profession.
Timeline
Assistant Manager Production & Manufacturing Engineering
Tata Advanced Systems Limited AIRBUS C-295
04.2023 - Current
Assistant Manager Production & Manufacturing Engineering
Tata Advanced Systems Limited Boeing CH-47 & Pilatus PC-12
04.2022 - 03.2023
Senior Production Support Engineer
Tata Advanced Systems Limited Boeing CH-47 & Pilatus PC-12.
04.2020 - 03.2022
Production Engineer
Tata Advanced Systems Limited Boeing CH-47
04.2015 - 03.2020
Assistant Manager
Tata Advanced Systems Limited
01.2012 - Current
Production Jr. Engineer
Tata Advanced Systems Limited Sikorsky S-92
01.2012 - 03.2015
B.SC AME - Aircraft Maintenance
Singhania University, Rajasthan
Aircraft Maintenance Engineering - Aircraft Maintenance Engineering
Sigma Aviation Academy, Hyderabad
Intermediate -
Guntur vikas junior College, Hyderabad
Class X -
Vignan vidyalayam, Hyderabad
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