**/*, **.********* ***** Extension,
Aiming for Senior Managerial Position to head the Plant Operations with
P&L Responsibility in a reputed Engineering Industry
Over 28 years’ experience in Strategic Planning, Manufacturing Operations, Systems Reengineering, Safety & Process Management and Quality Management with reputed organisations in India and Overseas, including 8 years of experience as Profit Center Head with Profit and Loss Responsibilities, New Product Development, Product Costing & Supply Chain Management.
Skilled in Design, Development, Management of Robust Processes, Methods and procured Capex machineries, Instruments for achieving Productivity enhancement and Reduction in Rejection Levels & Costs as per Budgets. Well versed with PPC, Material Management, Vendor Development, Logistics & Inventory Management.
Successfully implemented Green Field Project of MPVC Pipes and Brown Field Project of UPVC Pipes & PE Pipes with AS/NZS Product Standards accreditation and also Brown Field Projects of NNPB Process in Glass Bottles manufacturing with accreditation of ISO 9000 and FSSC Standards Certifications & Customer Audits of SabMiller, Budweiser, Carlsberg and United Breweries etc.
Effective Communicator with Strong Leadership, People Management, Industrial Relations & Union Handling, Coordination, Statutory Compliance, Interpersonal Skills and Analytical Skills.
Well-versed with Quality Management approaches like Lean Practices, 5-S House Keeping, Kaizen, Quality Circles, TPM, TQM, WCM and Six Sigma Master Black Belt Certified Professional.
Hindusthan National Glass, Pondicherry as Vice President-Operation (Dec'15 onwards)
(An ISO 9001 & FSSC Certified Company. Engaged in the manufacture of Glass Containers for Breweries, Distilleries, Pharma and Food Industries)
Accountable for the Overall Profitability of Pondicherry Plant with close coordination with all plant operation activities to meet the agreed organizational Performance Targets within agreed Budgets and Timelines.
Top Line growth increased from 100 crores to 175 crores & Turn Around the company as Profitable Company In Line with Stake Holders Satisfaction.
Process Improvements in Glass Homogeneity and achieved the Thermal Efficiency of 98% from 88% level. Hence the overall Production Efficiency increased from 85% to 92%.
Initiated Customer Satisfaction Drive and achieved "No Customer Complaint" continuously for last 18 months.
TOC Improvements in Foundry operations & Mould Shop through Continuous Process Parameters Monitoring and achieved Production increase from 392 cavities to 625 Mould Cavities per month and Rejection level reduced from 40% to 5% level with the total cost savings of Rs.12 crores per annum.
Cost Saving initiatives driven in Shrink Film Production, Forging components in place of Casting components & Energy utilization and achieved the savings of Rs.3 crores per annum.
Up to date with the current political and economic changes that impacts business performance, legislations and operating rules and regulations while proactively develop relationships with the local government including Safety, Environmental, Legal and Factory requirements.
Southern Pressure Casting, Chennai as Plant Head (Apr’13 - Dec'15)
(An ISO 9001 Certified Company. Engaged in the manufacture of Aluminium Pressure Die Casting Components for Automobile, White Goods, Agriculture Industries)
Responsible for Overall Plant Operations involving Production, QA, Maintenance, Stores, New Product Development, Marketing & HR departments.
Turn Around the Business and achieved the turnover increase from 15 crores to 50 crores.
Productivity Improvements in CNC Machine operation through Cycle Time Reduction with the help of EdgeCam Software and Value Stream Mapping.
Effective implementation of MSDS in Shop Floor & 100% Cost saving achieved in Machine Shop Coolant usage and 50% Cost saving achieved in Foundry Die Coat usage.
Firewall Inspection Standards introduced to achieve 100ppm for WOIL components.
Al-Jazera Factories for Steel Products Limited, Jeddah, Saudi Arabia as Plant Head (Mar’10 - Feb’13)
(An ISO 9001 Certified Company. Engaged in the manufacture of ERW Steel pipes and Tubes)
Responsible for Plant Operations involving production of ERW Steel Pipes to the tune of 7000 MT per month.
Desired Quantity was achieved by proactively and effectively interfacing with Production Planning, Surface Coating, Galvanizing, Quality Assurance, Maintenance, Tool Room, Safety and New Product Development.
Recorded savings to the tune of 100,000 Saudi Riyal through the implementation of a Design for Six Sigma Project for 3 meter Pipe Processing in Galvanizing Plant.
Engaged execution of 2 Black Belt Six Sigma Projects on “Galvanizing Process” and “Welding Process”. As a result, achieved 108 grams of Zinc saving per Pipe in the Galvanizing Process and 45% productivity in Tube Mill with the tune of 800,000 Saudi Riyal Saving.
Conceptualised and implemented Lean Improvements, which covered savings of Zinc and Reduction of Zinc Ash & Dross rejection by 20%.
Tubemakers & Roofmart (South Pacific) Limited, Fiji Islands as GM (Profit Centre Head) (Nov’04 to Oct’09)
(An ISO 9001 and AS/ NZS Product Standard Certified Company. Engaged in the manufacture of UPVC, MPVC, Polyethylene Pipes & Plastic Fittings and ERW Steel Pipes and Roofing Iron Products & Accessories)
Accountable for the overall Profitability of Tubemakers & Roofmart.
Instrumental in setting up a New PE Pipe Plant to manufacture Polyethylene Pipes with Colour Stripes, thereby avoiding 80% imports of pipes in Fiji Islands from Australia & New Zealand.
Setup New Factory by adding New Pipe Plant (Green Field Projects) to manufacture MPVC pipes with existing UPVC Pipe Plants (Brown Field Projects) with accreditation by AS/NZS Product Standards.
Export of UPVC, PE, MPVC pipes to New Zealand and the nearby islands to improve the revenues from $6 million at the time of joining to $15 million through Turnaround Management & Strategic initiatives.
Recorded an increase in Productivity by 30% in the PE, PVC pipe plant and by 150% in the Tube Mill plant.
Achieved 10% cost reduction in UPVC & PE Pipes through Productivity Improvements.
Achieved 18% EBIT sales ratio.
Acrysil Limited, Bhavnagar, Gujarat, India as General Manager (Operations) (Jun’01 to Oct’04)
(A QS 9000 Certified Public Ltd. Company, Involved in the manufacture of Plastic Extrusion & Injection Moulding Components for OEMs in the Automobile Industry & Building Material Industry)
In charge for the overall operations of their Extrusion Division.
Maintained the smooth functioning of Production Planning, Quality Assurance, IR & Union Management, Design and Development, Maintenance, Marketing and Training. Also proactively implementing Kaizen, Quality Circles, 5S, DOE and Cost Control.
Modified the design of calibration unit, which proved critical in resolving the 800 cc Moulding Roof Fitment problem. As a result, unit achieved 90% supplier rating from Maruti Udyog Ltd.
Succeeded in bringing down the rejection rate of PVC Moulding Roof from 5% to 3%.
Holds merit for recording productivity improvement to the tune of 45% in Extrusion Process.
Kabra Extrusion Tecknik Limited, Daman, India as Manager (Assembly) (Jul’97 to May’01)
(An ISO 9001 Certified Company & manufacturer of Plastic Extrusion Machines)
Answerable for Assembly and Production In-charge in Blown Film, Sheet and Pipe Plants.
The role demanded planning of various production activities with regard to Mechanical Assembly, Electrical Assembly, Die Assembly & Paint Shop and co-ordination with Purchase, Planning Engineering, Quality Assurance, Trial and Testing to achieve the targets.
Pivotal in the implementation of Value Engineering & cost reduction measures in 3 layer film plants and achieved Rs. 2450 per plant. Also Registered 65% time savings in terms of plant specification sheet preparation work by migrated seamlessly from manual to computerized operations & Attained 30% productivity improvement owing to the introduction of pneumatic tools like nut runner, pneumatic tapping machine and pneumatic screw driver.
TI Cycles of India Limited, Chennai, India as Executive (Production) (Feb’95 to Jun’97)
(ISO 9002 Certified Company & Reputed manufacturer of Bicycles for Exports)
Evolved from an individual contributor to leading teams.
●Played a stellar role in the introduction of Value Engineering concept in Aluminium Alloy Cable route Roller to Nylon, which resulted in net saving of Rs. 70,000 per year.
●Achieved the successful implementation of POKA-YOKE in Handle Bar Assembly and Saddle Assembly.
●Recorded productivity improvement to the tune of 10% in stands fixing operation with an introduction of pneumatic nut runner.
GEC Alsthom India Limited, Chennai, India as Asst. Manufacturing Engineer (Jan’90 to Feb’95)
(An ISO 9001 Certified Company & Involved in the manufacture of Electrical Protection Equipments)
Handled Relay Feeder Assembly Production, Planning and Control as well as Latest Manufacturing Techniques implementation. Also involved in designing of New Jigs, Tools and Fixtures in Shop Floor.
Achieved proper utilisation of idle machine capacity by designing and manufacturing fixtures & tools that were required for various assemblies.
Reduced Rejection Rate of coils from 2% to 0.7% in coil winding section and Augmented Productivity for Disc Element and Disc Relay Assembly by 20%.
MBA (Finance) from Indira Gandhi National Open University, New Delhi, India 2018.
PG Diploma in Materials Management from Annamalai University, Annamalai Nagar, Tamil Nadu, India in 1993.
Diploma in Production Management from Annamalai University, Annamalai Nagar, Tamil Nadu, India in 1992.
M.E. (Mechanical) from Birla Institute of Technology and Science (BITS), Pilani, Rajasthan, India in 1989.
B.E. (Mechanical) from Thiagarajar College of Engineering, Madurai, Tamil Nadu, India in 1988.
Training Programmes Attended
Six Sigma Green Belt, Six Sigma Black Belt & Six Sigma Master Black Belt
OHS Modules 1 to 6
JIT & Kaizen
SAP Business One
50 Years old (Date of Birth: 25th June, 1967).
Fluent in English, Tamil & Hindi.
Passport No. Z2399783 (Issued at Chennai, India. Valid up to 11th March, 2023).
LinkedIn Profile: https://www.linkedin.com/in/anbalagan-kathiresan-5484a422/