MAHESH RAMASAMY

email: ac6cro@r.postjobfree.com

Contact: 995-***-****

MANUFACTURING MANAGER

■ Career Profile

An experienced Assembly / Production manager from an electrical engineering background, with invaluable managerial 15+ years experience in various Automotive Components, Control Valves manufacturing (MNC) Industries. Highly focused with a comprehensive knowledge and understanding of various sectors such as large size Machine shop /Assembly unit with Health and Safety, technical services. A consistent track record of successfully employing best business practices that improve efficiency, reduce operating costs whilst increasing productivity.

Results-driven and dedicated with wide-ranging experience planning and leading operations involving small- to medium-sized manufacturing environments. Track record devising, evaluating, and implementing continuous process improvements to minimize waste and reduce costs while maximizing quality and yield

Strong interpersonal skills and ability to effectively interact with all levels of external and internal customers.

Build Dynamic teams Expertise in across operational areas spanning Manufacturing, Assembly and Maintenance functions. Mentored performers and Forged a unified and highly motivated team

Establishing effective quality control and safety programs, encouraging proactive participation across the manufacturing floor.

Expertise in improving existing Assembly/Production lines of business & coming up with new business technical ideas, leading the implementation of new lines of business

Demonstrated leadership and management skills, including an ability to effectively coach, motivate, empower, develop and evaluate employees.

■ Core Experience

Lean production systems/ AWO implementation ideas

ISO standards (ISO 9001:2008 & ISO 9001:2015) and TS 16949

Knowledge in API ( 598) ASME., ANSI standards

Process Automations / Digital ideas, TQM,JIT, Kanban,Kaizen ideas & 5S, (TVS experience)

Health & Safety, Environment( OSHA)

MTBF, MTTR analysis & Downtime elimination, Energy management systems

■ Professional Experience

GE Oil & Gas, Dresser Valve India Pvt Ltd, Eachanari, Coimbatore, Tamilnadu-641021

Total Experience in this Organization: 11 Years

Current Role:

Logistics / Warehouse Manager (Jan- 2017 to Till Date)

Responsible for shipping, receiving, inventory and transportation operations while directing warehousing activities for 60 team members including 14 supervisors through 3PL. Established operational procedures for activities such as verification of incoming and outgoing shipments, handling and disposition of materials and keeping warehouse inventory current.

Implemented daily safety discussions and monthly safety committee meetings resulting in Zero incidents

Achieved and maintained a 99.95% inventory accuracy level of service ensuring to meet production & assembly line requirements

Ensuring daily kitting deliverable to assembly /production line as per KPI metrics as level loading

Implemented Lean & digitized picking sequence and replenishment process based on equipment usage reducing 30% TAKT time

Reduced inventory on hand from $8.6 million to $6.7 million through converting non moving inventory and removal E&O parts

Reduced Dock to Stock cycle time by 30%, while implementing lean flow / Moving pallet line with clear.

Production / Assembly Manager (From 2011 - 2017)

Manage a matrix organization with cross product support from Machine shop, Assembly and Testing. Perform managerial functions such as daily production planning, labor reporting, root cause analysis, and budget control to meet organizational goals and objectives.

Coordinating direct customers/third party inspectors along with Final quality team to further Final inspection point’s closures. (Saipem, Saudi Aramco, Sinopec-China Petroleum, Chevron, Shell, Reliance, NTPC, BHEL, Samsung, L&T )

Selected Contributions:

Implemented Digital / Lean visual monitoring system of entire production line improving OTD improvement from 88.3% and 96 % consistently.

Reduced staff by 20% while maintaining production levels through a redesign/Automation of operational processes and improved training and staff utilization

Negotiated and reduced manufacturing and consumable materials cost by 20% to maximize the product margin

Developed capacity plan through Lean Digital, increasing Direct Labor Efficiency from 66% to 75%.

Identified the process delays through Spaghetti chart study and implemented various process improvement through Lean Action Work Out benefiting assembly operations 15 % Cycle time reduction

Implemented Automated Painting and Drying system, benefitting 25% the valves painting cycle time reduction

Introduced Auto Spray painting system,benefiting painting consumption cost reduction of 8% and improvement on Painting Quality

Increased 30% machine utilization efficient through reduction and elimination of major 16 losses

Implemented Just-in-Time (JIT) production methodology to control costs and inventory, resulting in a 20% improvement in efficiency for the Raw materials

Achieved Zero safety incidents in continuous 3.2 years through improved employee engagement and proactive engineered solutions

identifying and transitioning work to outsourced vendor, reducing total manufacturing costs by 30%

Day to Day Responsibilities

Monitoring Daily assembly/Production target, reporting to management in Tier 1 meeting

Working with Quality team and taking correction/ containment action for the Customer complaints

Identify, diagnose and resolve operational, manufacturing and maintenance problems within deadlines.

Plan work flow, manage multiple priorities and meet daily production targets while consistently meet the deadlines.

Reporting Daily Production numbers, including customer complaints corrective actions

Effectively lead, coach and develop a large work team to accomplish operational objectives.

Certified ISO 9001 Internal Auditor, supporting annual continuation of certification and recertification audits for plant’s ISO certifications

Developed new procedures and processes to improve production accuracy.

Setting up health and safety audit procedures and improve safety efficiencies.

Competently utilized Lean Manufacturing, 5S, SPC and related process improvement techniques to ensure the most cost-effective manufacturing process.

Establish and maintain acceptable quality levels for all assigned products.

Lead the "cultural change" of the organization by implementing Lean Systems and 5S methodology

Estimating & Budgeting for manufacturing capacity, production and materials control, assembly facilities, maintenance, and other manufacturing support activities

Facility /Maintenance Manager (From 2007 - 2011)

Managing all Maintenance activities(Electrical & Mechanical); Eliminate breakdowns of equipments by proper planning/execution of preventive/predictive maintenance plans

Maintaining the administrative office facilities and ensuring the availability of various daily requirements in order to ensure a harmonious work culture for the employees

Responsible for Budgeting- Preparation of annual & monthly Target control plan for –Breakdown, Repair and Maintenance Cost, Utility energy consumption

Liaison with Govt.Office (TNEB, TNPCB, Fire Dept) for statutory compliance & documentation Regulation, Plant safety control.

Work Experience (Previous)

Audco valve India (Larsen & Toubro ) – Kanchipuram - Assembly/Maintenance Incharge- (2004-2007)

Brakes India Ltd,Brake Division, Vellore,TN, Engineer CNC Maintenance - (2002-2004)

Sakthi Auto Component LTd – Erode,(Supervisor Machine shop- Maintenance - (1997-2002)

Educational Qualifications

Masters Degree in Power systems Engg (PT) – Anna University, Coimbator-2015

Bachelor Degree in Engineering (PT) – Karphagam University- Coimbatore-2008

Diploma in Electrical Engg- Nachimuthu Polytechnic-1997

C- license issued by Taminadu Electrical Licensing board-2005

Certified ISO 9000 QMS Auditor- BVQI -2012

System Experience:

MS Office, Oracle, SAP, C++

Personal Details:

Address : No,83, Annamalai Nagar, Malumichampatti, Coimbatore-50

Language Fluency : English, Tamil.

Date of Birth : 21.03.1979

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