Manufacturing Customer Service

SreeRam Mangalampalli

**** ********* **., ****** *****, IN-47119. Ph: 859-***-****. e-mail: *************@*****.***

Director of Quality/ Continuous Improvement/ Process Improvement

Lean Management/ Lean Consulting/ Continuous Improvement /Quality Management/ Change

Management / Process Innovation/ Lean Deployment/ Lean Education/ Cost Reduction/ Operations

Expertise

7 years of experience with Lean Management/ Consulting. 2 years experience in Quality

Management. Fields related to Management of Continuous Improvement/lean promotion department;

Implementation of lean manufacturing; Organization and coordination of continuous improvement (Kaizen)

activities and just-do-it improvement activities; Identification and removal of 8 wastes, 3 burdens (muda, mura,

muri); Application of Toyota Production System (TPS), JIT/Pull, 5S, poke-yoke, value stream mapping, mixed

model sequencing or level-loading (heijunka), SMED process, kanban production systems, zero quality control,

and visual controls; Standardized work charts. Facilitation of productivity events, quality events, value analysis

and value engineering events.

Work Experience

May 08 – Present: Director, Quality and Cont. Improvement at Kimball International, Jasper, Indiana

Kimball International is a major manufacturer (Annual revenue $1.2B) in two of its business segments: Furniture and

Electronics Manufacturing. It has approximately 6000 employees worldwide.

My duties include leading the departments of Quality and Continuous Improvement at National Office Furniture, a

brand of Kimball International with approximately 1200 employees across 4 plants and headquarters.

Selective Achievements:

• Managed 2 departments consisting of approximately 40 employees including Quality Managers, Continuous

Improvement Managers, Continuous Improvement Leaders, Quality Technicians and Inspectors.

• Reduced top Customer Complaints by 50% in 12 months. Elimination of top 3 categories from the top 5

categories.

• Company earned Bronze award in 2009 Office Furniture Dealer Association. The association graded us

against other competitors in the industry on various topics such as quality of service, product quality etc.

• Company won the Supplier of the year award from National Business Furniture, one of the major customer

in the company. The company as graded on a range of metrics from Product quality to On-time Ship.

• Received lowest number of customer product complaints ever in the history of the company in June 2010.

• Introduced programs such as Quality counts daily calendar, complaints reduction challenge, days without

configuration errors, increased process audits, increased incoming inspection, increased vendor product

inspection etc.

• Maintained the registration for ISO 9001-2008. Combined the registration of 5 units into one in 2009.

Bolstered the Quality System of the company through the implementation of a Common Process Audit

system, Plant wide process audit system and Daily local process audits.

• Managed 3 six sigma projects related to Seating Fabric Appearance, Paint and Concealed damage.

Duties related to Director of Continuous Improvement listed below.

Jul 07 – May 08: Director, Cont. Improvement at Kimball International, Jasper, Indiana

Kimball International is a major manufacturer in two of its business segments: Furniture and Electronics

Manufacturing.

Detailed Format

My duties include leading the department of Continuous Improvement at National Office Furniture, a part of Kimball

International.

Selective Achievements:

• Developed and implemented successfully a Lean Internship program that is not just self-sustainable but

offers its participants 6 credits as a part of two business courses from Vincennes University, Indiana.

• Helped develop bench strength to the company through the lean internship program so that the future

leaders of the company are competent in implementing concepts of Continuous Improvement in every

department of the company. So far, we graduated 70 employees from the program and 20 more are on the

path to similar success.

• Oversaw over 150 kaizen events in the company across various functions.

• Increased market share or beat the Office Furniture market for 12 straight quarters.

• National was profitable in Kimball during the recession.

• National reduced its inventory levels from 40% in 18 months.

• National increased its productivity during the last 3 years consistently. 350K(2.3%) in FY 09 and

1.1M(5.8%) in FY 10.

• National improved its employees’ safety by 99% in the last 3 years. It has been 2 million hours since we had

an injury in one of plants.

Jan 05 – Jun 07: Lean Implementation Engineer at Kaba Mas Corporation, Lexington, Kentucky

Kaba Mas Corporation is world’s largest manufacturer of high security electronic container locks.

My job responsibilities included training all employees in lean thinking process, motivating employees to analyze

company procedures, leading process improvements using lean techniques, coordinating recommendations and

changes that will enhance company procedures through a reduction of wastes, assisting in the implementation of

improvement procedures.

Listed below are the lean activities organized at the company:

Lean Management Activities: Design of lean events, value stream mapping, team formation, goal determination,

team leader selection, lean event scope determination, lean event documentation, action items maintenance and follow-

up, education and standardization of procedures, company lean presentations.

Continuous Improvement (Kaizen) Activities: Documentation, accounts payable, accounts receivable, order entry,

purchasing, proforma, manufacturing orders, ship date standardization, Multi-sourcing, parts and keys manufacturing,

drop shipments, batch orders, invoicing, outsourcing, activation-deactivation of customers, communications, shipping,

returns, tool identification process, product validation testing, project development.

Just-do-it Improvement (Kaikaku) Activities: Engineering department re-structuring, Product development cycle re-

design.

Few lean achievements in the company are:

Improved flow in all the above processes; Reduced product development cycle from 2 years to 9 months; Combined

Product Analysis and Reclamation department with Customer Service department for efficient communication;

Restructured Engineering into cross-functional product teams from functional teams to improve product design flow;

Improved job descriptions; re-allocation of inventory locations; consistent shipment dates.

Summer 03/04: Intern at Semicon Associates, Lexington, Kentucky

Semicon Associates is one of world’s largest suppliers of dispenser cathodes and rare earth magnets.

My job requirements were implementation and training of lean manufacturing techniques at Semicon Associates

especially in the magnets manufacturing facility and the cathodes assembly area.

Listed below are the lean activities performed at the company:

Lean Management Activities: Education and training of Lean basic lean principles such as 5S, visual controls, 8

wastes, standardized work, set-up reduction, batch size reduction, development of teamwork.

Just-do-it Improvement (Kaikaku) Activities: Cellular design of Samarium Cobalt powder manufacturing floor

layout, cellular design of magnets assembly area, cellular design of cathodes assembly area.

Continuous Improvement (Kaizen) Activities: Design of Kanban production system, application of visual controls,

reduction of inventory, design of mixed model sequence for magnets manufacture.

Detailed Format

Few lean achievements in the company are:

Decreased Cycle time to 2 weeks from 5 weeks in the magnets manufacturing facility; Re-designed shop floor;

Achieved 100% employee buy-in, and increased Labor capacity by 100%; Achieved 100% on-time delivery for the

first time in 8 years; Improved visual management of facility; Improved teamwork; Improved flow; Improved

Inventory control; Educated and applied lean techniques such as 5S, Standardized work, Root cause analysis etc.

Aug 03 –Dec 04: Teaching Assistant at University of Kentucky, Lexington, Kentucky

Worked as Teaching Assistant for ME 310- Engineering Experimentation-I, Theory and Lab sections. Taught over 100

students. In-charge of the lab for 2 semesters. Duties include lab management, teach students on experiments in

Instrumentation, grade lab reports and involve in grade determination decision making.

Aug 98 – Apr 02: Tutor, Various Educational Institutions, Hyderabad, India

While attending undergraduate college, taught high school students and engineering undergraduate freshmen for

almost 4 years. Taught different courses related to Physics, Algebra, Calculus, Coordinate Geometry, Probability

and Statistics. Also managed engineering educational institutes and other tutorial centers.

Education

Master of Science, Mechanical Engineering, University of Kentucky, 2002-

2006

Specialization in Lean Manufacturing: Lean Operations Management, Management for a Lean System, Lean

Manufacturing: Principles and Practices, Lean Value Stream Design, Design of Lean Manufacturing systems,

Leadership for Lean Enterprise, Organizational Learning for Lean Thinking, Lean Manufacturing Simulation, Systems

for Factory Information and Control, and Ergonomics.

Bachelor of Science (B. S), Mechanical Engineering (Mechatronics),

1998-2002

Jawaharlal Nehru Technological University, Hyderabad, India

Certification

Certificate: 2003

Lean Manufacturing

Center for Manufacturing, University of Kentucky, Lexington, Kentucky

Certificate: 2003

‘Lean Manufacturing Simulation’

Center for Manufacturing, University of Kentucky, Lexington, Kentucky

Computer Experience

ERP packages: SAP, Microsoft Great Plains, Profit Key, Citrix ERP systems.

Packages: Microsoft Office Visio 2008, ARENA 2001, Pro-Model,

AutoCAD, MiniTab.

Programming languages: C, C++, MATLAB, Fortran

Operating systems: Windows Vista, XP, UNIX, LINUX

Word Processing and Spreadsheet Software: MS Office 2003

Other related projects

Oct 03 – May 04: Indi-Go

We were placed 5th (out of 80 schools) in Elevator pitch competition at Rice University Business Plan Competition Harvard and

MIT. We presented a concept called Indi-Go, an Indian fast food center in United States. Successfully opened beta site, on

campus at University of Kentucky, in 2004.

Aug – Nov – 02: Autobox

The single order packaging line at Amazon.com called the ‘Autobox’ was not achieving designed throughput. The purpose of

the project was to study the line and improve the throughput using lean manufacturing principles and study various issues

Detailed Format

regarding machine downtime, ergonomics and conveyance. We studied the line, brought out many root causes for the line

breakdown, realized many places for improvement in the system and suggested the corrections to be made.

Detailed Format

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