Manufacturing Engineer

Jagannathan Ramachandran

Phone: Mobile 217-***-**** Home: 217-***-**** 1111 Windham ct,

Email: ***************@*******.*** Bossier city LA

71112

Leading the change ~ Transforming organizations ~ Manufacturing Executive

Passionate, innovative results driven management professional with

multifaceted experience in manufacturing industry. Lean manufacturing

expert with proven track record in productivity improvements that increased

the operating profits. Able to transform the organizational vision into

simpler goals and persuades others to achieve those. A history of

significant profit, volume & customer satisfaction achievements, which

illustrate the ability to combine cost control, revenue growth and process

improvements through effective personnel training & motivation.

STRATEGIC PLANNING TEAM BUILDING PROJECT

MANAGEMENT

PROFITABILITY IMPROVEMENTS SIX SIGMA LEAN

MANUFACTURING

CHANGE MANAGEMENT LEADERSHIP STAFF

DEVELOPMENT

Orica USA Inc. Watkins CO

Mar 09 - Present

Orica is the world's leading manufacturer of mining explosives &

services for commercial mining industry.

Corporate Lean Six sigma Black Belt

Transformation of three manufacturing sites operationally and to

embrace lean six sigma culture as way of life& deliver an EBIT of

$1Million.

Accomplishments:

. Increased the throughput by 94% through cross functional

team using lean principles of VSM, flow & RCA in the

booster optimization project.

Advanced Filtration Systems Inc. ? Champaign IL

Aug 04 - Mar 09

AFSI manufacturer's fluid filters & systems for Caterpillar diesel

engine applications to serve their OEM & off highway vehicles markets.

AFSI operates with four automated production lines and 250 non union

employees.

Program Manager Sep 08 -

Mar09

To provide leadership and coordinate the design, manufacturing and

integration supply chain functions for next generation filter

assemblies to enhance profit margin and prevent the recurring

design issues.

Re layout the two filter manufacturing lines to increase the

profitability by floor space & labor optimization

Continuous Improvement Manager Sep 07 - Dec 08

Lead the implementation of continuous improvement through five

personnel department & mtg. team.

Improvement of existing process and products through continuous

improvement principles

Deployment of lean manufacturing tools such as Rapid

improvements,5S, VF, QCO, Kanban, Pull & VSM

Promote the continuous improvement culture inside the plant.

Accomplishments:

. $34 Million revenue capacity plan was presented to

management to meet forecasted demand with two year ROI.

. $5Million reduction in capital expenditure using lean

plant layout for AFSI -Europe

. Delivered $1 Million savings by converting 24x7 to 24x5

operations.

. Optimized supply chain inventory for Chin Precision by

creating inventory management plan.

. Created the Rapid Improvement program through employee

empowerment & learning

. Developed & executed the strategic annual plan for the

department.

Lean Manufacturing Engineer Sep 05 - Sep 07

Lead the implementation of Toyota production system principles

through high performance zone teams.

Improvement of existing process and products through continuous

improvement principles.

Deployment of lean manufacturing tools such as 5S, VF, QCO, Kanban,

Pull & VSM

Promotion of the TPS culture inside the plant.

Accomplishments:

. $125,000 savings by reducing changeover time at spin

forming loader by 20 mins.

. Provided comprehensive management training in Toyota

production system.

. Prevented customer shutdown by leading a kaizen event

for waviness of synthetic filters.

. Improved capacity through better packaging methods and

eliminated 4 temporary positions.

. Developed tools for capacity & capability of machines to

facilitate better decision making

. Challenged "status quo" & Inspired people for higher

performance

. Led numerous kaizen workshops with significant

improvements.

Manufacturing Engineer Aug 04 - Sep 05

Provide engineering support to the production line at beading,

spin forming processes & assembly area.

Design & development of new products &processes

Design tooling to support the new products & ensure

functionality, quality and cost of products

Improvement of existing process and products through continuous

improvement principles

Research, recommend, purchase and install the new machines.

Key Accomplishments:

. Designed tooling to reduce changeover time at assembly

gantry by 15 min with savings of $100000

. Launched the new product 1809 Base assemblies for

Caterpillar.

. Improved & standardized the process of design &

development of Urethane molds

. Exhibited excellent project management skill through on

time installation of Centrasep cleaning system with in

budget

Collins & Aikman Corporation ? Morristown IN

Jan 03 - Aug 04

C&A Morristown operations is a 300 employee unionized plant that

manufactures class "A" automotive interior and exterior components to

Toyota, GM, Chrysler, Ford & Mitsubishi. The operations include

injection molding, assembly & paint processes.

Continuous Improvement, Engineering Change & TS-16949 Coordinator

Aug 03 - Aug 04

Lead the implementation of lean manufacturing, coordinate the

TS:16949 certification & Eng. changes

Coordinate the conversion of QS9000 to TS:16949

Coordinate engineering changes across all department's to ensure

on time completion.

Develop the process audits for continual evaluation as per TS:

16949

Key Accomplishments:

. Teamed with engineers to develop FMEA's & Control plan

for new products

. Successful conversion from QS9000 to TS:16949 &

recertification

. Developed the measurement system for document controller

& continual EC review process

. Improved the document control change time by 80%

. Developed Activity Based Cost estimation for 2005 Ford

Mustang parts.

. Created the plant profile presentation for GM-Hummer

business.

Continuous Improvement Coordinator

Jan 03- Aug 03

Provide training & assistance in implementation of Toyota

Production System for associates and plant management through

empowered teams, lean workshops & kaizen team activities.

Identified target areas for improvements and accountable for the

implementation of best practices. Continuous improvement of

operational metrics -quality, cost & delivery.

Key Accomplishments:

. Created weekly waste reduction program that produced

$500,000 annual savings

. Reduced press changeover time from 75 min to 30 min with

$150000 impact to bottom line

. Generated $150,000 supplier cost reduction in Ford

console assembly parts

. Provided $70,000 cost savings through use of returnable

packaging.

. Redeployed 10 operators through kaizen activities with

impact of $294,000 to profitability

. Improved productivity by 40% through line balancing

activities in Ford console assembly

. Reduced floor space requirement by 29% through 5S

. Reduced machine down time by 8.3% through Total

Productive Maintenance

. Introduced lean in new product introductions to reduce

capital expenditures

Previous Experiences:

Center for Robotics & Manufacturing Systems -University of Kentucky,

Lexington KY 2001-2002

Maruthi Castings, Coimbatore INDIA

2000

LMW-GKDITR, Coimbatore INDIA

1999

Wheel & Axle Plant, Coimbatore INDIA

1999

Lakshmi Machine Works, Coimbatore INDIA

1998

EDUCATION

University of Illinois- Urbana, IL MBA

2006-2008

Master of Business Administration in General Management

University of Kentucky, Lexington KY MS

2001-2003

Master of Science in Manufacturing Systems Engineering (Lean & Operations)

Amrita Institute of Technology & Science, Coimbatore, INDIA BE

1996-2000

Bachelor of Engineering in Production Engineering

Skill Sets:

CAD/CAM/Simulation: SDRC-IDEAS, ANSYS, Auto CAD, CATIA, PRO-E,

Solid Works, Pro-Model, Arena

Programming: C, C++, VC++, VB, Oracle, SQL, Java, Microsoft office

& Project, IBM-Lotus

MRP/ Database/ Others: Oracle, Fourth Shift, SAP, Fanuc Robotics&

CNC controller, CNC Programming

Key Words: Lean mfg, TPS, Operations Research, Strategy, Automotive,

injection molding, Casting, machining. TPM. [pic][pic][pic]

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