Career Episode 1: Production Engineer at Roop Polymers Limited

Anuj Kumar, a Production Engineer at Roop Polymers Limited, successfully managed a project to enhance the efficiency of Gasket Manifold and reduce the reject percentage to the minimum level. He collected and analyzed data, proposed innovative approaches, and collaborated with the team to achieve the objectives. Anuj's technical skills and knowledge helped in proposing effective solutions and managing the roles and responsibilities of the staff. The project was a success and Anuj's contribution was significant.

COMPETENCY
DEMONSTRATION REPORT
Career Episode 1
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ANUJ KUMAR

CAREER EPISODE – 1
a) Introduction
CE 2.1 Project Details
Dates : [please fill]
Duration : [please fill]
Location : [please fill]
Name of the organization : Roop Polymers Limited
Position Title : Production Engineer
b) Background
1.2 Nature of the overall engineering project
I was assigned as a quality engineer in the Roop Polymers limited company,
which is responsible for manufacturing of plastic and rubber parts for automotive OEM at
the global level. I and my team was assigned with different duties for the enhancement in
the sales and efficiency of ten most popular parts including the Gasket Manifold, Fool
Rest, Fuse Box, Lunax Hose, Gasket, Pad Tank Cover, and many more. This project is all
about increasing the efficiency of the Gasket Manifold and reducing the reject percentage
of the gasket manifold to the minimum level.
1.3 Objective of the project
Following are the objectives developed for this project:
 To limiting and minimizing the rejection percentage of the gasket
manifold from 15% to 1%
 To collaborate within the team to accomplish the objectives
 To have a better and effective communication
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 To propose innovative approach that can help in making this successful
 To fulfil the needs and requirements of the consumers through presenting
efficient and effective approaches
1.4 Nature of your particular work area
I had collected the production and sales related data from previous years and
compared it with the present conditions. My team and I accomplished the activities
related to the making of the Die and Pin for extrusion. I had extruded pipe from
extrusion, and Ring cuted from slicer. I made the changes as per the needs and
requirements of the organization and customers and provide the best and efficient
services those can be provided.
1.5 Organizational structure chart: (Manufacturing)
Figure 1: project group of members involved in the project
1.6 Statement of your duties
I collected the data and analyzed them for the proposition of an effective
approach that can be delivered considering the market and the needs and requirements of
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the customers. I considering the enhancement of the efficiency and restricting the
rejection of the product from 15 % to 1 % developed the design related to the gasket
manifold. It was my duty throughout the whole project to make sure that the product is
capable of meeting the demands of the market and the efficiency of the products are
enough to be liked by the consumers.
c) Personal Workplace Activity
CE1.7 Technical details of the work
I transformed the previously used materials with the newly proposed objects such
as 6 GMS patti putting in transfer pot was previously used and it was replaced with the
1.70 – 1.80 GMs. Ring Putting IN BOP. I modified the system to be run as a compression
mould as previously, it was running as a transfer mould. I identified that previously
clamping pressure was 180 kg / cm square, which was replaced by clamping pressure of
80 kg / cm square. Other big modifications include the reduction of the number of
bumping from two to one and bumping pressure was reduced from 120 kg/ cm square to
the bumping pressure of 50 kg / cm square.
CE1.8 How you applied your engineering knowledge and skills
The works and activities applied resulted in the following figures that is showing
positive values for the organization and hence, the proposed modifications were
identified successful
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CE1.9 The tasks delegated to you and how did accomplish
I managed the roles and responsibilities of the staffs and employees of lower
grade assuring that they have been assigned with the workload that can be handled by
them without any extra burden. The proposed designs were exposed to them and the
production was made accordingly considering the same design. I had done mathematical
calculations and determination of the values associated with the products for the
determination of the most effective and efficient product.
CE1.10 Any particular technical difficulties/problems and how you solved
them
The rejection of the gasket manifold was the most crucial problem identified
during analyzing the data of the organization and it was identified that the rejection
percentage has been reached almost to 9.32 %. I identified it as a very big figure lagging
in this section and thus, new design and modifications were needed in manner to
minimize it to the extent level.
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CE1.11 Strategies devised by you including any original or creative design
work
I had implemented five changes as stated in the above section and those were
capable of achieving the objectives of the proposed project. All the changes were new
and innovative in manner to make sure that the rejection has been limited and the needs
and requirements of the consumers are being fulfilled. I successfully restricted the
rejection figures proposed in the above table and thus, enhanced the overall revenue of
the project in an efficient and effective manner.
CE1.12 How you worked with other team members
Collaborative work is one of my strength and I managed the effective
communication among the involved team members for the accomplishment of the
activities those can be helpful in achieving the goals and objectives of the project. I called
for the installment of the machines in manner to enhance the contribution of the
employees within the production section and enhancing the output of the organization. I
was under two executives with a partner by my side and I had to manage all the
individuals from the lower hierarchy and managed their roles and responsibilities within
the organization.
d) Summary
CE1.13 your view of the overall project
The project was a successful project and I get to learn about many new ideas
those were proposed by the team members. The innovation level was at high and all the
activities and responsibilities were managed in an effective and efficient manner.
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CE1.14 how the project fared in meeting the goals/requirements
I implemented the modifications and the amendments those were necessary for
restricting the rejection percentage an thus, the rejection percentage was restricted due to
the changes applied in then project.
CE1.15 How your personal role contributed to the project
I managed the project as a production engineer that helped in the identification of
the current market status and proposing the effective and efficient solution.
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