Engineering Engineer

MANOJ KUMAR PURUSHOTHAMAN

## Condominium Mutiara, Block E 17-09, Bandar Perda, 14000 Bukit Mertajam, Penang, Malaysia

Mobile Malaysia: +601*-******* Home: +604-******* *************@*****.***

S R. M A N U FA CT U R IN G E N G IN E ER / P RO D U CT E N G IN E ER

P R O C E S S E N G I N E E R I N G L E A N M A N U FA C T U R I N G S I X S I G M A G R E E N B E LT C E R T I F I E D

A G I L E P R O J E C T M A N A G E M E N T S TA K E H O L D E R C O L L A B O R AT I O N Q U A L I T Y C O N T R O L

(QC)

O P E R AT I O N A L L E A D E R S H I P P R O C E S S & S E R V I C E I M P R O V E M E N T S M E C H A N I C A L

DESIGN

T O O L, E Q U I P M E N T & P R O D U C T D E V E L O P M E N T C A D / C A M / P R O - E U T I L I S AT I O N

“Improvement usually means doing something that we never done before.” Shigeo Shingo

Senior Engineering Executive, offering 13+ years of progressive experience in product engineering,

new product implementation and development, process improvements, materials and resources

optimisation, cost control and operational streamlining across complex manufacturing environments

9.3 years of experience in the EMS industry, 2.4 years in Quality control and Production engineering

and 1.7 years in Product design. Expert in initiating sustainable cost-saving strategies and efficiency

improvements while boosting quality results. Extensive manufacturing experience, complemented with

strong expertise in Agile project management, LEAN manufacturing, prototype building, tooling &

equipment development, cross-functional collaboration and stakeholder management. Rich experience

in troubleshooting technical issues, coordinating multiple engineering activities, communicating with

clients and overseeing production operations and staff . Six Sigma Greenbelt Certified, with solid

experience in all aspects of NPI, ECO, BOM, PFMEA, FAI, and CAD/CAM.

SIGNATURE STRENGTHS

Bill Of Material Productivity Improvements Project Planning, Costing &

Management

Process FMEA First Article Inspection

Product Inspection & Audit

Manufacturing Engineering Cross-cultural Team

Collaboration Performance Analysis & Testing

Cost & Waste Reduction

Engineering Changes Design Assembly & Engineering

Data Management & Reporting

Multi-Stakeholder Engagement Vendor/Supplier Relations

Production Launches

Value Stream Mapping

Software/Technology: MS Office Pro-E Wildfire/2001 Unigraphic NX1&2 Solid Works AutoCAD

Baan ERP System

CAREER HIGHLIGHTS

FLEXTRONICS TECHNOLOGY Penang, Malaysia

Senior Process/Product Engineer 2005–Present

Acted as “Technical Lead” in delivering supervision, direction and administration to all design and

engineering initiatives covering New Product Introduction (NPI), General Availability (GA), and Field

Return Management for Box Build and System Integration. Managed and coordinated change requests,

product transitions and process improvement initiatives.

Collaborated with internal partners in implementing process and equipment modifications to obtain

continuous improvement and ease of operations. Produced and maintained engineering records, BOMs

and work instructions.

NPI & Sustaining Engineering, Lead Direct Fulfilment, FAI & Supplier Qualification & Tooling

Instrumental in the successful implementation of process optimisations from Electronic Card

Assembly (ECA) to Box-Build level, chassis integration/system integration through collaborative

engagements with business stakeholders

Employed exceptional process control and design expertise in partnering with the Development

team and Supply Chain on parts, Bill-of-Material (BOM)/Engineering Changes (EC) release process

and maintenance with multiple suppliers

Commended by the Senior management for executing seamless ECO implementation process

and management

Drove 92% increase in production performance by launching improvements in process yields,

reducing RMA and driving shop floor productivity to minimise defect and waste rates from the

process

Investigated risks/issues, determined root cause and implemented cost-effective solutions which

minimised downtime and eliminated manufacturing problems by 98%

Played a key role in the review, approval or modification of product designs, including

management of product transfer and new product set up as well as the validation of new processes to

ensure the highest quality of products

Carried out box level/Chassis level FA qualification on all components and subsystems

Led and architected lean manufacturing associated with Kaizen, Poka Yoka and small group

activity (SGA) that significantly improved on time delivery and generated cost savings for the

company encompassing Process Improvement, Manufacturing Lead Time and Quality Improvement

Manufacturing Lead Time Reduction Saving $65K/Year

Zero Defect Manufacturing Line Saving $156K/Year

Productivity Improvement Saving $8450/Month

Poka Yoka Verification tools for hardware and software Yield improved by 15% from

83% to 95% Saving $9K/Month

Poka Yoka Process Improvement Reduced cycle time by 50% for Packaging and 20%

for Packaging Cost

Launched seamless integration of LEAN concepts and culture to the entire manufacturing

processes that maximised resources (materials, tooling and equipment) and processes (delivery

time), resulting in lower costs, streamlined processes and production efficiencies

Aligned work processes with health and safety regulations; achieving zero accidents throughout

the production

Brought in extensive knowledge and experience in LEAN, Value Stream Mapping, 5S tools and

techniques

Direct Fulfilment (DOF/CTO)

Spearheaded Six Sigma Project (Green Belt) which increased capacity utilisation through

reduction of network downtime VPN (Oracle, Ship tool and IHC); supervised 4-member team

during the 5-month project period

Successfully led the Online Verification System project for OQA Station to verify hardware

components and software by utilising V-tool, ensuring all products delivered from chassis

integration department were centred on customer and end customer requirements; managed 2-

member team during the 4-month project duration

NESTECH CONSULTING PVT LTD India

Design Engineer 2004–2005

Applied sound knowledge and expertise in design, engineering and manufacturing processes to create

end products. Oversaw the modelling of Solid, Sheet metal and surface parts utilising various CAD

tools such as Pre-E wildfire, Uni-Graphics and Solid Works. Constructed Sub-assemblies and carried

out Assembling of sub-assemblies and components to shape the final assembly, including drafting and

detailing following customer specifications and standards.

Directed onsite project development and implementation from initial scoping of customer

requirements, coordinating materials and resources, setting project schedules and milestones,

communicating design plans, creating documentation and engineering reports and aligning product

specifications to overall client standards

Acted as “ Team Leader” in the training implementation and quality inspection of drawings and

models

AREMPEE HI-TECH EQUIPMENTS LTD India

Quality Control Engineer 2002–2003

Executed end-to-end delivery of quality assurance activities to ensure superior quality standards of

assembled instruments and devices. Determined assembly process capabilities and audited assembly

processes for performance and quality. Generated documentation and yield reports. Delivered support

and oversight to the Quality assurance leadership efforts related to product development. Established

constant communication with suppliers and customers to ensure quality issues were resolved and

properly handled. Facilitated internal weekly yield review meeting with team members.

Accomplish 100% yield, completing a full cycle inspection of outgoing and finished

materials/goods prior to delivery to end customer and to the warehouse

Rendered subject matter expertise and guidance to QA operators and certified specialists through

on-going trainings

Recognised for creating standard works and process flow for the production run

Communicated issues with the Supplier and drove corrective action plans based on yield reports

to minimise defects

Previously worked as “Production Engineer” at Auto Craft CNC Impex Ltd in India from 2001 to

2002

EDUCATION & C ERTIFICATION

Bachelor’s Degree in Mechanical Engineering Bharathiyar University, Coimbatore 2001

Diploma in Mechanical Engineering Coimbatore Institute of Technology (Sandwich Polytechnics)

1997

Six Sigma Green Belt Certified February 2007

M/Sc Nastran (FEA / FEM) Autodesk Certificate April 2001

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