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Manager manufacturing Engineering

Chennai, Tamil Nadu, India
June 22, 2019

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M.SENTHIL Mobile.: 882-***-**** Email:

Career Objective: A challenging position in a Manufacturing domain where my overall Production, Manufacturing Engineering and Project Management background, will be combined to render the most benefit to the organization. Profile Snapshot: Seasoned Manufacturing Engineering Professional with experience in Automotive seating systems, Railway products manufacturing and Auto ancillaries sectors – M/S Harita Seating Systems Ltd., M/S Harita Fehrer Ltd., M/S Johnson control automotive Ltd., M/S Faiveley Transport and rail technologies India (P) Ltd. & Bharat Seats Ltd. 15+ years experience in TVS group and 4+ years experience in US based MNC. Experience in both Green and Brown field Projects. Lean Practitioner. Academic background:

M S - Manufacturing Management from BITS, Pilani Sep 2009

Graduate in Industrial Engineering from IIIE, Navi Mumbai Oct 2004

Diploma in Mechanical Engineering - April 1998

Career Highlights:

1) Senior Manager-process engineering M/S Bharat Seats Ltd (Joint ventures of M/S SUZUKI, Maruti and Relans)

(Since Aug’17)

Manufacturers of Automotive seats, mechanisms, Two wheeler chassis, head and roof liners for automotive, Floor Carpet of automobiles Turnover- INR. 900 Crores / Annum,

Responsible for Process engineering function of the Plant, Process Improvement activities of running products, and flawless launch of new products.

Worked under guidance of Japanese Consultant Mr Kuramitsu San on the TPM implementation – Kobetsu Kaizen (Focused Improvement) Activities.

Customers: M/S Maruti Suzuki India Limited, Suzuki Motor Corporation Processes: Foaming, Assembly, Fabrication, Mechanism, Floor Carpet Moulding Facilities- 6 Palletised conveyor lines for seat assembly, 4 High pressure PU Foaming Machines, 20 Robos, 120 MIG/TIG welding machines, Power Presses, Automated Mechanism assembly machines. Achievements:

Productivity of Car Seat Assembly line improved from 480 seats / day to 850 seats / day. (4.8 seat sets/employee to 7.0 seat sets/ employee.

Capacity of the plant augmented from 1800 seat sets to 2400 seat sets (including all process Foaming, assembly and Fabrication).

Established Trim units with the capacity of 2400 car seats trim including leather trims as a part of backward integration.

Established the Facilities for model YCA (Wagon R 2019 ) as per the agreed timeline with Customer MSIL and Complete Traceability requirement .

Established Seat Belt Reminder System Testing at End of line Testing and inspection without affecting the productivity of the line. For the Models CIAZ, S Cross, VITARA BREZZA, WAGON R.( one of the regularity requirements by the Indian government on Vehicles).Highly Appreciated from M/S Maruti Suzuki India Limited 2) Manager Process Engineering, M/S Faiveley Transport and Rail Technologies Ltd ( A WABTEC Company ) Hosur ( Jun’16 – Aug’17)

Manufacturers of Railway Products for Indian Railways and Metro Trains – Rs. 900 crores Turnover/Annum Customers: Indian Railways, ALSTOM, BOMBARDIER, SIMENS, HYUNDAI ROTEMS, BEML, Product range: HVACs, Pantographs, Doors, Brakes, Brake Panels,Couplers. Achievements:

Established the HVAC Manufacturing assembly lines and augmented capacity of 1 unit / day to 3 units / day with complete traceability of the product.

Improved productivity of the Door Assembly line from 1 unit / day to 4 unit / day by reducing the Standard man hours.

Implemented Quality improvement Projects of Door Assembly – 1) Sealant Applications automation, 2) Chemical Cleaning, 3) Automatic Door Handling, 4) Packaging of the Door.5) Vacuum Curing of Bonded Doors,

Special Processes of Bonding and Sealant application have implemented with guidance of Group experts.

Implemented Wastage elimination projects – INR 15 lacs / Annum.

Improved On Time Delivery (OTD) to 95% from 73% on HVACs and Doors.

Reduced customer complaints to 5 nos. / Month from 12 nos. /month

Implementing Total Employee Involvement (TEI) activities. 3) Deputy Manager - Advanced Manufacturing Engineering, M/S Johnson Controls Automotive Ltd .

( Jun’13 – Feb’16)

(Johnson Controls is a US Based Multi National and Multi product Company presents in 156 countries across the globe, Manufactures of Automotive Seating and Electronics, Interiors, Building Solutions of HVAC Systems, Power Solutions Battery for all Industrial applications. Johnson Controls is a 120 BN USD organization) Manufacturers of Automotive Seating Systems, Mechanism, – Rs. 1200 crores Turnover/Annum Customers: Ford, Renault Nissan, BMW, Royal Enfield, Daimler India Commercial vehicles. Key Contribution:

Achieved Traceability data for the products collection and storage in the server first time in JCI-India History. Customer Renault Nissan Requirement.

Implemented and established Manufacturing Engineering Foot prints in Chennai plant in line with Johnson Controls Global Manufacturing Engineering standard requirements.

Established DOJO Cell – Training Cell to Train our Operators on the assembly line manufacturing processes benchmarking with our Japanese plant.

Implemented mistake proof system for different torque application in a single station with the single torque tool – Socket selector and Reaction arm with tool positioning sensor localization for DC Electrical tool implementation.

Developed Combination assembly fixture for Driver / Codriver Track to raiser mechanism assembly for RENAULT LODGY.

Developed Modular conveyor Pallets for Renault Nissan seat assembly conveyor line for all products in one line – Change over time reduction .

Developed all critical assembly fixtures to meet all the product / customer requirement for RENUALT LODGY – Compressed lead time of product development cycle time with the designed indent.

Implemented assembly fixtures and modular line for FORD ENDEVOUR model inline with our other plants to meet the global product Launch Requirement.

Achieved Flaw less launch of Complete seating Systems requirement for NISSAN TERRANO,

Achieved Productivity in the Production Assembly line by reducing work content from 1.2 Direct Labour Hours / EQU to 0.6 Direct Labour Hours / EQU ( MODAPTS study efficiency improvement, Layout Improvement, Material Movement Reduction, Line Balancing )

Achieved JCMS ( Johnson control Manufacturing standards ) Score by implementing JCMS principles in the Shop floor.

Achieved Right First time PPAP Approval from Customer RENAULT for BADGE ZERO Launch during PPAP lot itself. 4 ) M/S Harita Seating Systems – (July’ 1998 to May’ 2013)- 15 years Harita Seating Systems Limited, Hosur – TVS Group Company manufacturing seating systems for automobiles with a turnover of INR 750 crores.

The Career Path:

1998-2003 Production

2004-2009 Production Engineering

2009-2010 Projects

2010-2011 Process and New Product Implementation

2011-2013 New Product Development

Key Contributions;


Responsible for the Operations of Foaming, Welding, Powder coating and Assembly shops. Established a new manufacturing unit (Green field) at Ranjangaon, Pune.

Grabbed the opportunity to enhance productivity and Manufacturing Systems Engineering, under the valuable guidance of World’s leading Japanese Consultant. Mr. Takao Kasahara.

Worked as core team member and established the Plant expansion at Hosur by setting up the complete processes and machinery.

Worked in the project team for establishing powder coating facility

Actively Involved in Policy Deployment process

Facilitated and guided Supervisory Improvement Teams & Judge for Quality Control Circles (QCC) evaluation New Product Development – Program Management

Project Manager for implementing New Products for OEM’s TVS Motor, Volvo, Royal Enfield, Yamaha, Tata Motors, Ashok Leyland, John Deere, New Holland, AMW, TAFE, etc.

Leader of Cross Functional Team (CFT) consists of various functions.(both full time and part time members)

Implemented 16 new products in 2011.

Responsible for entire Program till obtaining approval on Part Submission Warrant (PSW) from customers.

Budget & Resource planning for the development and obtaining approval from Management for the Business case.

Developing product in accordance with ISO/TS-16949 and customer specific requirement.

Capturing customer requirement thro’ PPAP checklist / JRQS

Conducting FMEAs and DRs & Overseeing Proto manufacture and Testing

Incharge of NPD assembly cells for trial production

Frequent visits to customer on product finalisation & trials.

Organizing weekly Management reviews to update the status of the project to the Top Management.

Driving the activities to achieve targeted product cost

Accountable for QCD parameters of New Products till handed over to regular production. Achievements:

Implemented cost reduction projects to the tune of Rs. 45 Lakhs for four years.

Optimized the work force from the level of 320 to 145 in 5 years with an improvement in productivity across the manufacturing operations – Wall to Wall – (starting from inward to despatch) for the increased volumes.

Initiated deployment of Assembly automation and de-bottlenecking. Trainings Attended:.

Low Cost Automation (LCA) – at AOTS, Japan conducted in india - 1 weeks

Work Study and Work System design – NITIE – 1 week

Project Management - NITIE – 1 week

Pneumatics – Festo – 1 week

Quality Management System (QMS) by BVC - QS:9000, ISO/TS: 16949, APQP, PPAP, FMEA and Internal Auditor .

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