Sekhar Babu Talari

• Preparation of detail work scope of Wings and Fuselage for F-15 Eagle
• Preparation of complete scope of the project in detail
• Calculation of estimated man hours and analysis to fit the business case
• Preparation of Integrated master schedule (IMS) as per customer demand
• Define the activities, duration and preparation of complete deliverable
• Resource analysis and budget calculation
• Capacity study and analysis of 3M (Man, Machine and Material)
• Learning curve analysis , calculation of CPI & SPI (Cost and Schedule Performance Indexes)
• Crew Load / Swim lane charts & recovery schedule
• Ensure that all services are conducted in a safe, cost effective and environmentally sound manner, and fully meet all company and additional project specific requirements
• Baseline creation and track the actual performance against baseline and review the variance
• Execution, monitoring and tracking the product and update the project status for top management
• Tracking the material shortages, coordinating with the procurement team
• Preparation of inspection plans (internal as well as Customer and DCMA)
• variance analysis and report generation
• Calculation of VA & NVA to improve the productivity by reducing the NVA
• Assist with the co-ordination of necessary input from all departments and project team
• initiation, implementation of 5S culture
• Working on lean manufacturing concepts to reduce the NVA and improve the productivity.

Key projects/achievements

• Preparation and buy off the Master Schedule to customer as per the demand & sign off
• Initiated the kitting process to reduce the unnecessary movements/waiting time of the technicians
• Reduced skinning station duration from 170 to 70 days by utilizing the technicians,kitting, lean method and 5S
• Produced from 8 wings to 14 wings after implementing the kitting and lean methodology
• Manpower reduction/ saving done by 33.3%
• Validation of learning curves and proposal and preparation of multi station working mechanics in the factory

• Planning, scheduling, and Industrialization for the below programs

C-130J Super Hercules: Center wing box, Horizontal, Vertical stabilizer and leading edges

DO-228 NG (RUAG: Forward fuselage Wings and Leading edges

Pilatus PC-12 Aircraft: Wings, All the panel and floors, cockpit and leading edges

Cobham (Midair refueling pods): 908 & 808 series

Boeing 777 Upper lock box: Landing gear and AH6i Vertical stabilizer

Boeing -Chinook CH47 : Tail and Crown

Sikorsky -S92 Cabins: All the Panels and final integration

• Calculation of standard Man-hours by using MOST study and submit the project for business development team
• Calculation of Manpower based on the standard hours and realization factor
• Method study and time measurement by using MTM-MOST and MTM-UAS analysis
• Preparation of Crew load charts and line balancing
• Capacity enhancement and calculation of peak production requirements (Man, Machine and material)
• Learning curve analysis and derive the best fit curve to the program
• Establish the baseline, tracking, monitoring and execution of the project
• Calculation of EWT for the different shipsets/aircrafts
• Calculation of VA & NVA man hours, preparation of action plan and monitoring.
• Preparation of performance , Productivity reports and presenting to Top management
• Working on lean activities to eliminate/reduce the observed wastes

Key projects/achievements

• Planning, scheduling, and execution of 85 ship sets of aircraft assemblies (Horizontal /Vertical Stabilizer & Leading edges) for C130 J Super Hercules of Lockheed Martin.
• Submitted the program schedule for 5 years contract timeline and got signoff &approval from the customer in first attempt (Lockheed Martin Head Office, USA)
• Planning, scheduling and execution of Dornier 228 NG -Ruag aircraft assemblies, Pilatus PC-12 assemblies, Cobham midair fuel refilling pods (series 908+808+905+912), Boeing 777 - Upper lock boxes (LH+RH), Ah6i - Vertical Stabilizer, Chinook - CH47 aircraft assemblies (crown and tail cone), AH64 Fuselage in the span of 4 years 5 months
• Implemented 5S culture and standardized IE reporting system
• Established barcode and andon system to escalate instant alerts to supporting functions during the work stoppages
• Standard time analysis by using MOST for Boeing 777 Upper Lock Box and improved the productivity Validated learning curve and saved the resources by 15%

• Responsible for the calculation of the standard time for the models /variants by using MTM-UAS study

◦ Skoda -Laura, Superb & Yeti

◦ Audi -A4 and A6

◦ VW- Vento and Passat

• Work guideline preparation and line balancing each technician/operator wise
• Calculation of VA & NVA, task/operation wise, station and plant.
• Working on lean manufacturing to reduce the NAV with the help of Spaghetti charts
• Performed the enhancements under KVP cascade along with the mother plant Skoda team
• Working on the expansion of Audi lines to increase the production from 6 to 10 cars
• calculation of productivity and reports generation

Key projects/achievements

• Saved 28 resources (manpower) by applying the MTM study in Skoda Aurangabad-for the variants Superb, Laura and Yeti.
• Improved the productivity of the Audi line by 22%

• Analyzed the standard timings using MTM-UAS system in paint shop by MTM-UAS for the models of

◦ Fiat- Punto, Linea, and TATA Manza

• Preparation of work guidelines and defining the total manpower required
• Preparation of HPV reports
• Optimized capacity through Lean principles and reduced variance between sites by global best practice sharing
• Acted as a Coordinator for World Class Manufacturing (WCM) paint shop for workplace organization pillar

Key projects/achievements

• Improved the utilization of resources in paint shop -FIAT auto India 40% by conducting the Line balancing and working on WCM-Workplace organization pillar

• Worked in bodybuilding shop & Assembly line for Savari, Bolero camper, Load king line as an Industrial engineer
• Responsible for calculation of standard time by using MOST (Maynard Operation Sequence Technique)
• Manpower planning and line balancing for all the different variants on the single line
• Calculation of Effective Working Time (EWT) and rebalance the lines once after stable
• Worked on value Added and Non-Value-Added analysis to improve the line utilization and productivity

Key projects/achievements

• Increased Productivity by line balancing with MTM standards & thus saved 15 resources from the line in Mahindra & Mahindra.

• Completed Masters in Industrial Engineering stream with 1st class

• Graduation in Mechanical engineering-1st class