Ref. No. : CA - 17234 - (Quality – with 31 years in Plastic Industry)

Education

Post Diploma in Plastics Mould Design (PD-PMD) from (CIPET), Chennai in 1994

Diploma in Mechanical Engineering From TamilNadu in 1991

Skill Sets

Machinery & Equipment selection
Installation & Commissioning
Project Execution
Servicing & Trouble shooting
Production &Plant Operations
Machine Maintenance
Mould Maintenance
Process Improvement
Production Planning

Work Experience

Manager – Operations
May - 2013 to Present
Company Profile: Manufacturer of Mufflers, exhaust systems, exhaust manifolds, vehicle body products, impact door beams, other automotive parts, cold forged products, cold finished steel bars, drawn pipes, carbon steel pipes for mechanical structures, machined/ground steel bar products etc.
Job Profile:
Responsible for selecting, purchasing, installing & establishing fully robotised (Robots from Panasonic, Japan) welding line controlled by Mitsubishi PLC Systems, Electrical power supply installation, Diesel Generator Air Compressor, Support Structures & piping etc.,
Developing quality systems & procedures to meet RNAIPL’s ASES, PSW & T2000 requirements & completing the audits
Accountable for completing HVPT & SOP production in progress as scheduled
Implementing TPM practices and achieving productivity targets & setting new bench marks with the help of ‘ongoing’ Kaizen activities
Making Annual action plan for Major 6 Key Measurables of the company goals & achieving the same through team efforts.
Developing Quality circle Teams & motivating them to solve their problems by themselves by using 8D technique.
Planning all resources including Man Power, Raw material & consumables etc., based on customer forecast on monthly basis.
Responsible for achieving Production, Training & Operational Cost Targets.

Highlights:
Reduced the Manual operation Cycle time from
113 sec to 94 sec by working out on SWCT& made various Kaizens
Reduced Quality Gate Concerns from 56 a month to zero, by using Poka Yoke, Training & Facility Creations as more Lighting, Boundary Samples, Feeler Gauge & Micro Tip Pencil on location etc.
Solved Minor issues in Line stops & Quality problems through Quality Circle teams.


Senior Manager – Projects & Maintenance
Apr - 2010 to Apr - 2013
Company Profile: The company is one of the largest suppliers of moulded parts, assemblies & module supplier to the Indian automotive industry. MATE manufactures a wide range of plastic components and fully equipped facilities to support customers in  the automotive and the non-automotive segments.
Job Profile:
Heading the Establishing &Maintenance of a world-class Moulding Plant after setting up& commissioning from the greenfield stage in Bangalore spread in 11330Sq Meter built up area.
Supervised the complete project infrastructure activities like Civil construction, piping, Electrical Cable laying, earth pit construction, Fire Hydrant, Fire Protection & Alarming Systems, public addressing systems, In plant & security lighting system (Philips), LPG Gas Bank (Super gas) etc.,
MTU Diesel Generators from Sterling Wilson (2 x 1010 KVA), 1600 kVA Transformer (from Voltamp), Synchronised Load Distribution Panels (Lotus Power Gear), PCI, Germany made Flywheel UPS for Uninterrupted Power supply to the entire plant’s critical loads (2 X 625 KVA)
Installed & commissioned other utilities like Over Head Cranes 25 +10Ton , 10 + 3 Ton and 3 Ton Capacities (Electromech with ABUS hoists). Chillers (York), Closed loop Cooling Towers (Evapco), Lubricated as well as Oil free Air Compressors(Atlas Copco), Circulating Pumps (Grundfoss), Water Softening plant (Crone), Water Treatment Chemical dosing systems, Established Paint Sludge formation & Removal practices etc.,
Fully robotised Body colour Paint shop (from AES Japan, Fujitronix Japan, Kawazaki, Japan),
Centralised Automatic Material Conveying & Drying Systems & Granulators (from Piovan, Italy) & Robots for Injection Moulding Machines (from Yushin, Japan, Wittmann Austria)
20 Nos of Injection Moulding Machines include All Electric (from Niigata, Japan&Toshiba, China) & Hydraulic Injection Moulding Machines (from ENGEL, Austria, Haitian, China & Negribossi, Italy) from 75 tons to 2300 tons, 6 Nos. of Blow Moulding Machines of 80 Ltr. Capacity each (from YOUNG IL, Korea & Chen way , Taiwan)
Achievements
Established the Maintenance Department with very young & Fresh Team. Achieved Most improved Unit from Group Chairman among 49 Units audited in & around India for the Maintenance Systems being practised.
Established effective Water Treatment system & achieved literally no scale deposition in any of Machines & Moulds for the past 2 consecutive years.
Up time of Equipment achieved above the Target value 99.4 % throughout the last Financial Year & revised the Target to 99.6 % to the current FY & achieving above the same (99.8% till date). Moving towards Condition Monitoring & Predictive maintenance, wherein aiming to eliminate the breakdowns completely.
Established the Robotised Paintshop, with joint efforts from Production &Maintenance Practices brought to the level of 96% FTT (First Time Through)
Exceeded the target of MTBF (Mean Time Between Failures) of 250 hrs consistently throughout the last FY & increased the Target to 517 hrs & exceeded the same.
Made many Kaizens& Automations through Team effort & saved rejection losses & cost to the company. To name a few Automatic SMS messaging when BESCOM Power fails / resumes, Idle run cut OFF for Motors in Injection Moulding machine, Temp based VFD Control for Cooling Tower fan Motor, etc.


Technical Manager
Aug - 2007 to Feb - 2010
Company Name: Shongai Packaging Industries Ltd.
Job Profile:
Spearheading the new projects & maintenance of the equipments & Moulds with a team of 25 professionals.
Negotiating & following up with suppliers on issues related to installation & commissioning and performance of mould & machines; developing & implementing strategies to increase their running efficiency.
Establishing long term relationships with key suppliers and customers; coordinating with customers on all issues related to the supply of articles.
Attending to various technical faults; holding discussions with mould & machine suppliers to ensure effective rectification of all problems.


Senior Executive – Quality Assurance
Jan - 2007 to May - 2007
Company Name: L&T-Demag Plastics Machinery Limited
Job Profile:
Ensuring quality of all machines supplied through a team of Quality Assurance Engineers.
Overseeing the installation & commissioning of machines through a team of engineers all over India & abroad.
Working in close coordination with departments for service issues of machines in warranty & beyond warranty.
Resolving quality issues by taking up directly with all suppliers.
Conducting quarterly Quality Review Meet; coordinating with the Marketing and Manufacturing Team.


Service Head
Sep - 1994 to Jan - 2007
Company Name: Larsen & Toubro Limited
Job Profile:
Handling the installation & commissioning of machinery, auxiliary equipment, centralised material conveying systems and moulds; undertaking preventive, predictive and breakdown maintenance.
Focusing on Key Customers like by providing Technical solutions like Conducting Mould trials; Machine capability & Process capability studies, optimising the process for obtaining best quality component PRICOL, G Plast, Sundaram Plastics, Auto Plast, Tata Auto Plastics Systems, SSF Packaging, ITW-Signode, Vaidya Group, Rinder India, Minda, Supreme, Varroc, Mould Craft, Anchor, Cello etc.,
Maintaining the warranty spares stock at office.
Generating service revenue through AMSC, Customer Training Programmes, Non Warranty Service, Machine Up gradation, etc.
Working in close coordination with Field Engineers & various departments of Manufacturing Unit.
Training the customer personnel on working principles of machinery and maintenance.
Rated as Top Performer for last 3 years of my career in L&T, consecutively

Core Competencies :
Working out various requirements, monitoring overall project operations & ensuring timely completion; setting-up standards, ensuring optimum utilization & deployment of available resources to achieve organisational objectives
Monitoring the activity at sites and project schedule, ensuring the cost control within the budget and planning for cash flow requirements
Anchoring & planning erection & commissioning for various equipment and machinery
Coordinating with Key Customers, Service Engineers, Application Engineers, and (Machine Manufacturing) Factory, keeping track of all the issues & resolving them.
Making Complete plant layout of Machinery & Utilities. Selection of Machinery & Equipment based on the process requirements.
Managing Installation & Commissioning of Plant Machinery within the planned time. Executing the projects (Electrical Cablings, Air & Water Pipe lines and Civil works) with various Contractors & guide them to achieve the same as per planned schedule by tracking through Gantt Chart&using Toyota’s techniques [Denwachoo plan  (Hourly monitoring of plan), Catch up plan for pending works, Counter measures for the concerns etc., ] 
Monitoring & ensuring adherence to quality systems & comply with ISO 9001& TS 16949 quality standards and maintaining requisite documents (Certified as Internal Quality Auditor in ISO TS 16949
Planning, implementing & monitoring technological changes to enhance productivity; identifying scope for modifications in equipment, process flow, practices for controlling & reducing conversion cost per unit.
Managing a team of Engineers & Technicians and guiding them to address and resolve performance bottlenecks along with imparting in-house training. 
Practicing Lean Manufacturing, Kaizen, Poke Yoke & FMDS techniques everyday

Future Goals

growth

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