Ref. No. : CA - 17693 - (Production Planning - Plastic Products and Processing – with 28.9 years in Plastic Industry)

Education

P.G.D.P.P.T, From  CIPET, Bhubaneswar in 1995

B.Sc (Chemistry) From  Thiagarajar College in 1994 

Skill Sets

Packages Known : MS Office, Auto CAD(Basic)
Operating System : MS Dos, Windows
ERP Development : Developed for Operations, Job involves decide requirements, writing spec, Implementation, monitoring operational performance, bottlenecks will be resolved with the help of software
professional.

Ability to identify problems in process, machine, mould, suggest & implement solutions by design. 2. Aspiration to learn from any corner to meet technical challenges.  
Involving, guiding, supporting people and getting the job done. Professionally mature, good  communication & inter personal skill. 
Positive attitude to work, believes in teamwork, good organizing capability
Self Starter, Self –motivated & Self-confident 

Work Experience

Plant Head 
Since Jul 2010 
Company Profile: Leading Manufacturer & Supplier of Automobile components, cycle components
Profile: A Management Position utilizing my skills in identification of new and alternate development resource of potential suppliers which offers Economic value addition to Organization. Elimination of waste & non value added activity. Job involves coordinating with Customers, Daily operations, meet out 100% supply requirement, Utility, Civil, starting from Scratch. Coordinate with the suppliers for a new plant, civil, electrical, mechanical contractors. Commissioning
Job Profile:
Reporting to MD.
Leading a team of 5 Managers & 12 engineers with a work force of 320 persons team to ensure the day to day Customer requirements & meet the targets with the specified time.
Responsible for new business development & new project development.
Control subcontracting activity & vendor evaluation.
Maintain optimum inventory in all areas.
Stringent monitoring for Imported materials & high end value materials & CKD parts.
Reconciliation of material in house & vendor end.
Value addition minimum 5 to 10% every year.
Run the 70% of the M/c’s in fully auto. Periodic reviews and budget control.
Reduction of premium expenses in all categories including fuel.
Ensure the compliance of TS-16949 requirements.
Motivate and manage the performance of Subordinates
Ensure teamwork and effective communication both inter and intra department
Promote integrity and adherence to organization culture and Values

Achievement:
Apart from automotive company has entered into Electrical & Commodity industry.
Schneider requirements are strictly followed & awarded with the business.
New business has been received from Dymos, Borgwarner & Samsung.
Started from project & achieved the TS-16949 on time.
Out sourcing concept has been followed to increase the capacity.
A time & motion study has been conducted & based on that robots have been installed.
Optimum utilization of space for FG & SFG.
No of Customer supply vehicles is reduced from 12 to 9. Value addition of Rs – 34 lakhs incorporating on line assembly.
Diversified from automobile to electrical & own products.
Designed a plant with my experience utilizing the maximum space (without architect), adhering to the Government norms & got the approval for the same. 95% of the project work is completed on time, Production is started, currently heading the plant.
Cost saving in project is Rs – 3.85 crores.

Manager Injection Molding
Apr 2008 to Jun 2010
Company Profile: Engaged in manufacturing assembly of air conditioners and plastic components. Its products include refrigerators
Profile: Job involves M/c Finalization, Utility, Civil, starting from Scratch. Coordinate with the Architect, civil, electrical, mechanical contractors. Commissioning of M/c’s, Utilities & project has to be completed on time
Job Profile:
Reporting to MD & VP.
Leading a team of an Assistant manager & 3 engineers to ensure the project requirements.
Based on the target date reverse working has been done & GYR status has followed on a daily basis.
Cost reduction of purchasing the capital goods.
Techno commercial comparison of capital equipment’s.
Coordinating with Customer & meet the targets with the specified time.
Coordinate with suppliers to manage the lead time to complete the project on time.
Verification of project bills as per plan & actual.
Value addition for the project
Coordinate with the Government authorities for the regulatory requirements.
Coordinate with Customer to get the business – awarded.
Evolve Develop & Establish long term sourcing strategy with the supply base.
Implementation of Lean manufacturing practices.
Tool correction for flash free molds.
Value addition of products to be reviewed with Customer.
Assembly concepts to be implemented in the molding stage itself.
Management of Customer audit, statutory audit, internal audit, supplier audit
Plan and allocate resources for Supplier Scanning, Selection and development of potential suppliers for various commodities.
Periodic reviews and budget control.

Achievement:
Completed the project on time – 9 months
Cost saving in civil – flooring up to 62 lakhs by calculating the actual requirement.
Double bus bar is recommended to utilize the DG & EB to manage power.
Stage wise load has been obtained from TNEB W/o any delay.
Coordinated with customer & completed the I phase capacity in 3 months & made the unit to run in 85% capacity.
Paint shop has been established & put in to operative.
Commissioning of M/c’s & trials has completed as per the customer target date.
New project costing has been done & awarded the with high volume tools.
Financial year April 09 to March 10 cost savings 8 millions

Strategy adopted:
Project savings – 6 Millions,
Waste elimination – 0.5 Millions,
Alternate source – 0.5 Millions,
Negotiation – 1 Millions
Handled the SCM without any premium cost & got the best supplier award from Customer

Assistant Manager 
Apr 2006 to Apr 2008
Company Name: Daejung Moparts Pvt Ltd.
Company Profile: Manufacturing Plastic molded parts & assemblies. (Automotive applications)
Job Profile:
CFT Team Member for ACH & Ford export project.
Meeting customer monthly schedules without compromising quality.
Effective utilization of equipments, responsible for P& L in the department.
O Customer end rejections. No Line stoppage @ Customer end.
Optimizing operational cost in terms of 4M.
Process Improvements & Reduction of wastage.
SLP launch date to be strictly adhered for new programs.
5S & 3C Improvements in shop floor.
Review individual deliverables. Periodic reviews & budget control.
Ensure teamwork and effective communication both inter and intra departments.
Ensure proper usages and reconciliation for raw materials and consumables.
Scrap should be less than 0.5%.

Achievements:
Door warpage is eliminated by a design change. Kanban is maintained in fan assemblies.
First time reached `O’ PPM & `O’ QR at Customer end, awarded with engineering plastics in bigger parts weigh up to 1 kg, with a value added (assembly) process.
Repeated problems in 27 molds are avoided by minor modifications in the mold.
Assembly line is balanced in 3 parts and productivity raised up to 44%.
Cost saving by using regrinds 2 million per year, rework 0.5 million/year.
Smaller tonnage M/c’s are effectively utilized by back plate modification in the molds.
Implemented basic concepts of TPM in shop floor, by introducing My M/c & TPM tree.
Reduced manpower from 9 to 4 in an assembly process by increasing productivity.
SMED arrangements are implemented in small tonnage M/c’s.
Visual displays of SPC Tools are implemented in the shop floor.
Done the analysis for non-moving of material & utilized within 2 months, consumed 28 tons of material

Sr. Engineer Export Operations
Dec 2004 to Mar 2006
Company Name: Motherson Automotive Technologies & Engineering
Job Profile:
Team Member for Webasto & Air International & Ford export projects.
In-Charge for new Tool, Masterbatch, Material trials & buy offs of tools.
Improve the quality of HMIL products by training the team.
Weight reduction in feed systems.
Team Leader for SMED, Engineering, Process and new PROJECTS.
Standard operating Procedures to be implemented.

Achievements:
Went for new tool trial in Noida.OTD is achieved for Air International- Australia.
Warpage in HMIL products (4 nos) was avoided.
Dust problem is reduced 60% in paint shop by an improvement.
Pareto is implemented on daily basis for rejections, rejection reduced to 1.3%
Involved in Tool buyoff for new projects
Coordinated with Suppliers & got the tools on time.
Warpage in Webasto sun roof frame is sorted out by tool modification & Fixture

Supervisor
May 1998 to Nov 2004
Company Name: Cavin Plastics and Chemicals Pvt. Ltd
Job Profile:
Joined at the project stage and involved in erection & Commissioning of M/c’s.
Worked as Shift In charge.
Taken care of development activities in Production.
From January 2004 taken care of machine maintenance as an additional responsibility.
Reaching the production target without compromising quality.
Cost reduction in trimming devices, sprays & also by weight reduction.
OEE has to be increased from 77.48% to 85%.
Form 8 inspection date has to be confirmed before 20 days.
Noise levels have to be controlled within the limit by providing silencers.
Trial Samples has to be submitted within the lead time.
Value addition / Functional suggestion minimum one in a quarter.
Improve entrenchment level from 62% to 75%.
Learning’s & near misses has to be recorded.

Achievements:
Processed PET with conventional screw barrel assembly.
Rearranged Compressor pipe line with ring meal type to prevent pressure drop.
Quick fix coupling for molds and mold standardization.
Pulley modification in extruder to increase output of a product by 70%.
Cooling manifolds in machine platens. Unscrewing & Flip cap molds are through.
Three dimensional spacer & back plate standardization in molds.
Developed an SPM for punching (Hole dia – 0.8mm) of VACO Tube

Production In-charge
Aug 1995 to Apr 1998
Company Name: Siv-Sen ready plast, Madurai
Company Profile: 6 Injection molding & 4 Compression molding Machines
Job Profile:
Taking care of Production, Maintenance & Material planning.

My contribution :
280gm bucket is got produced in SP-180 (maximum stroke)
Tie rod breakage is avoided by mold & M/c alignments.
Cycle time of a pp bowl mold reduced by effective cooling.
18 molds design is changed within a month.
Spares are provided & down time are reduced.
Twin barrel for double color injection molding.
Increased the production of relay cover to 40%.

Training : M/s. Cincinnati Milacron Ltd, Ahmedabad.
Planned maintenance CII
Best shop floor practices CII
Leadership skills CII
5S training programs External
Internal Auditor Training External
Good manufacturing practices External

Machines handled :
Injection Molding M/c’s
UBE – 1800T to 650T, Mitsubhsi – 1200T to 650T, FCS 60 to 1250T
Ferromatik Milacron 1800T to 650T, Haitian 1600T, Super master 450T to 1200T.
Engel 25 T to 1500 T, Arburg 35 T to 75T.
Windsor SP Series –600T to 130T, Borch 120 to 320T
Cincinnati Milacron Sigma 400T to 80T; Magna –770T,660T, Welltec-160T,
Hyundai – 650 T to 150 T, Battenfield 200 to 60T, Nissei 80 to 150T.
Extrusion Blow Molding M/c’s: CMP – 500, 200.
Stretch Blow Molding M/c’s: Micro Tools – 1L, Arun – 500ml, Print Link – 2L

Materials Processed :
PC, ABS, POM, PPS, SAN, PET, NYLON, HIPS, PS,
PMMA, PP, HDPE, LLDPE, LDPE, Santroprene, PVC,
Some of the special purpose materials from SABIC

Personal Strength: 
Ability to identify problems in process, machine, mould, suggest & implement solutions by design. 2. Aspiration to learn from any corner to meet technical challenges.  
Involving, guiding, supporting people and getting the job done. Professionally mature, good           communication & inter personal skill. 
Positive attitude to work, believes in teamwork, good organizing capability
Self Starter, Self –motivated & Self-confident

Career Summary:
Have 20 years functional experience in manufacturing, Majority of experience in molding environment with additional responsibility handled Projects & Improvement activities. 
Have involved in productivity increase by optimization of mould, machine, process & involving people. 
Have knowledge & hands on experience in Injection, Extrusion Blow & Stretch Blow molding.  
Have undergone training in Cincinnatti Milacron on Injection molding machines. 
High degree of focus in cost reduction exercises & optimization process.
Ownership & Commitment with initiative to keep the machine idle hour zero to process. 
Developed the existing ERP to a close loop system from the initial entry (fool proof).
Have Project knowledge, started 2 projects from scratch. Core team member of a 100 Crore group.

Future Goals

To obtain a position that not only utilizes my experience but also offers challenge, excitement and the opportunity for intellectual & professional growth.

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