Bharat Forge Limited

June 2023 - Jan 2025

Assistant Manager

• Collaborated on major defense artillery projects including MGS 155x39 Caliber, ATAGS 155x52 Caliber, Garuda 105, and Naval SRGM 76 Caliber for the Indian Armed Forces.
• Created accurate 2D/3D CAD drawings, part modeling, and assembly using NX and Solid Edge for manufacturing and documentation.
• Designed and developed defense-grade machine tools, selected appropriate materials, and applied GD&T for precision drafting.
• Created multi-stage CNC turning process plans and detailed 2D drawing layouts for barrel development.
• Designed long machining test fixtures and inspection test rigs to ensure dimensional and performance accuracy.
• Generated multiple design iterations to improve product durability, reliability, and manufacturing efficiency.
• Implemented a data-backed consumption trend analysis (over 2 years) for machining tools and inserts used in MGS and ATAGS defence programs, leading to proactive procurement planning, reduced QA bottlenecks, and improved tool inventory accuracy, ultimately saving man-hours and minimizing downtime.
• Led cost-saving initiatives aimed at achieving robust and optimal production volume.
• Spearheaded new product development from concept through prototyping and final application.
• Conducted tolerance stack-up analysis for assembly precision and performance.
• Developed critical production documentation, including Manufacturing Quality Plans (MQPs), gun barrel drawings, Inspection Test Plans (ITPs), cycle time charts, and Tooling SOPs.
• Led a cross-functional team of mechanical, electronics, embedded, and software engineers for full system integration.
• Established in-house manufacturing capabilities for automated machine tools used in defense production.
• Implemented lean methodologies like 5S, KAIZEN, TPM, and Tooling SOPs, resulting in reduced human fatigue and enhanced productivity.
• Developed and validated defense tooling and fixtures that improved machining capacity and part accuracy.
• Managed Bill of Materials (BOM) and Engineering Change Notices (ECNs) across multiple development stages.
• Conducted non-destructive testing (NDT) including Ultrasonic Testing, Magnetic Particle Inspection, and Optical Borescope Visual Testing.
• Standardized defense inspection documentation for product size and tolerance verification.
• Handled tooling cost planning, CAPEX distribution, and cost center allocations for monthly shop floor operations.
• Created standardized shop-floor documentation such as cycle time charts, ID inspection charts (for DHD and honing), and straightness analysis reports.
• Supervised and led operations including lathe machining setup, autofrettage, deep hole drilling (DHD), honing, and threading.
• Performed data collection and analysis of production cycle time in MS Excel for accurate production forecasting.