Manager Maintenance

Balasubramaniam Ramu

Personal Particulars

Age : 48 years old Date of Birth : 12 Sep 1967

Nationality : Malaysian Gender : Male

Marital Status : Married with 3 children

Address : ****/** ***** ***gi, Off Jalan Reko, Kajang, 43000 Selangor,

Malaysia

Telephone Number : +603-********

Mobile Number. : +601********

Email : ********@*****.***

Educational Background

Masters in Engineering (M Eng) Field of Study : Engineering (Mechanical)

Major : Manufacturing Systems University: National University of Malaysia (UKM)

CGPA : 3.87/4.00 Graduation Date: May 2009

Masters in Business Admin. ( MBA ) Field of Study : Business Administration

Major : Operations University: National University of Malaysia (UKM)

CGPA : 3.53/4.00 Graduation Date: Apr 1999

Bachelor's Degree ( BSc.(Hons)) Field of Study : Physical and Applied Science

Major : Physics University: National University of Malaysia (UKM)

Class : 2nd Lower Graduation Date: Apr 1991

Certificate

Completed Configuring Windows Server 2008 : Active Directory and Network Infrastructure course on Nov.2010.

Employment History

FP Industries Sdn. Bhd.

Position Title : FACTORY MANAGER Duration: Jun 2011 – Jun 2015

Nature of Business: Plastic Injection Molding and Thermoforming for Food/Non Food Packaging : Containers, Spoons, Lids, Tubs and In Mold Labeling(IML) and Shrink Sleeving Labelling

Responsibilities:

Managing the Plant Operations with 200 workers and 5 department heads.

Manage direct report – Production, Planning, R&D, Maintenance, Facilities and Tooling Dept Heads

Indirect responsibility for QA and HR department task and issues resolution

Development of new product, material for testing and process improvement

Conduct weekly planning meeting for planning, production, tooling and maintenance planning

Daily follow up on production status, delivery update and machine and mold status.

Management of discipline procedures, managing worker attendance, discipline, training and skills management to reduce attendance issues

Maintaining rejection rate via close monitoring and data tracking.

Spare parts maintenance for machine and tooling to enable fast repair and response for breakdowns

Lead new material and product trial and testing

Lead process flow, process improvement activities to minimize unnecessary task.

Handle robotic arms troubleshooting and programming issues via communication with supplier in Malaysia and Switzerland.

Conduct product improvement, mold modification for overseas customer and conduct trial at their plant in Australia

Achievements:

Reduction of product mixing error and elimination of calculation issues

Machine troubleshooting and training of technical staffs

Handling facilities maintenance and troubleshooting

Cost saving up to RM500K via direct sourcing

All new product trial implemented successfully.

Reduction of downtime via proper maintenance plan and spare parts maintenance

Tooling department reduction in mold breakdown with improved service and procedure

95% compliance to customer delivery

Weekly planning reduced unnecessary maintenance call back

Reduction of overtime by better manpower planning and management of contract workers

Improvement in plant safety thru more awareness and enforcement

Successful modification and trial result for overseas customer products

BC Signedge Sdn. Bhd.( JV UK/MY)

Position Title : OPERATIONS MANAGER Duration: Jun 2007 – May 2011

Responsibilities:

Managing the production, planning, maintenance and engineering departments.

Daily organization of production operations with manager and assistant manager.

Providing support on production issues, productivity improvement ideas.

Setting up new working standards, procedures and process flow to improve operations and communications

Working with stores personnel to improve stock balance, stock take and stock management on monthly basis

Managing maintenance work in the machinery and plant facilities

Producing production plans for customer based on orders and target delivery dates

Working with procurement department on material requirement, order quantity and dimensions as well as follow up delivery plans

Setting up discipline procedures, managing worker attendance, discipline, training and skills management to reduce attendance issues and dismissal of problematic workers

Motivating team by creating activities and get together session between the production team and the management.

Maintaining cost of product within given budget via cost saving activity, production rationalization and improving how process are done.

Overall management of the plant, production, maintenance and human resources.

Drive projects on facility improvement, lighting and work area modifications, plant layout improvement, materials organization improvement and staff skills upgrade

Work on ergonomic improvement to bring better working condition to the workers.

Achievements:

Managed to reduce cost of production via improvement activities in amount over RM20K per year, mainly related to process reduction, parts rationalization and involving in better design.

Created new system to enhance Bill of Material creation so that each department can access and order the required parts easily and faster, time reduced from 2 weeks to 3 days.

Created new information flow and communication for production floor which resulted in much less mistakes on production, supplier and sub con with better inspection methods

Time study conducted for production process resulting in more accurate planning and lead time information to the customer

Have achieved 100% delivery on schedule to customer and have had 0 customer complains in term of delivery and quality to the customer.

GoemarLaboratoires, St. Malo, France (French MNC)

Power Container Corp, New Jersey, USA. (American MNC)

Position Title : Project Manager Duration: Apr 2004 - Apr 2007

Responsibilities:

Working at Geomar Lab in France for 3 months and then at Power Container Corp., NJ, USA since June 2004, working on new product development, machine modification and efficiency improvement projects. Work on Productivity improvement for all production lines via line study, QC tools, Pareto Analysis etc.

Completed a feasibility study to move the plant operation to Malaysia with full set of set up costing and also production start up facility calculation in Malaysia.

Implementation and training for relevant crew on SMED.

Development of PM system for all machines with the local technical crew.

Identify and analyze technical issues on production machines and developing new solutions for production machine downtimes and loss time.

Identify new process improvements and implement on the production lines.

Work with the printing suppliers to improve the quality of the print and suggest proposals to the marketing and sales department.

Work together with Injection Mould parts supplier on new parts, quality and design issues as well as technology transfer between plants.

Design new jig/fixture or machine parts to improve the process flow, machine function and output.

Being transferred to supplier plant in New Jersey USA to identify loss time issue and implement improvements to increase the productivity.

Developing a new machine to be used for prototyping new product and later developed into a full scale manufacturing machine.

Working with local team on plant layout development for new products as well as utilization of present space effectively.

Achievements:

Feasibility study completed, project viable for Malaysia transfer

Process improvement activities carried out resulted in rejects reduction in injection and assembly especially parts falling off from the conveying systems.

New machine/prototype successfully modified and was able to be used for new product testing.

Customer – managed to reduce customer complaint to zero at assembly line

Worked with French team to improve assembly line productivity

Huhtamaki (M) Sdn. Bhd. (Finnish MNC)

Position Title : Production Manager Duration: Mar 2001 – Apr 2004

Responsibilities:

Organizing and coordinating through supervisory personnel all production activities to manage all activities and production crew

Coordinates production activities among all relevant departments

Maintenance team management and development.

Employ, Develop and Train all employees

Manage Discipline and resolve related issue of all production employees

Work towards Customer Focus by ensuring quality standards are met

Develop and pay Productivity bonus according to productivity level

Develop, plan and carry out Plant and Machine scheduled maintenance

Identify critical control point and promotes HACCP practice

Develop Wastage team and work towards wastage reduction and cost saving

Achievements:

Production achieved positive result for the year 2001 with good production results in paper cups, injection molding and flexographic printing departments.

Reduction of material wastage resulting in 30% reduction of customer complaints.

Developed service contracts and relationship with Atlas Copco, UMW and DOSH,JKKP,BOMBA to enable proper maintenance to be carried out

Printing machine output up by 30% via SMED and planned maintenance program. Coordinated and carried out major parts replacement and set up on the Drusula flexographic printing machine

Developed training program for all existing workers and 39 new Nepalese workers. Nepalese workers showed positive contribution after 6 months.

Developed and implemented required discipline control for all production workers and managed to eliminate the negative factors with supervisors' assertiveness, which have been affecting the production and workforce morale.

Reduce the customer complain from 6 to below 3 per month and improved relationship with the sales and customers via training and process improvement

Developed HACCP procedures for all production processes, and lubrication and maintenance PM check sheets to be used by technicians for maintenance work.

Reduced the wastage in this area from 8% to 3 % via utilizing SMED and proper set up procedures.

Colgate Palmolive (M) Sdn. Bhd. (American MNC)

Position Title : Team Leader Duration: Oct 1998 - Mar 2001

Responsibilities:

Function as the production SAP helpdesk and trainer.

Develop TPM activities in the Powders and Bars Focus Factory.

Lead the SMED project team.

Coordinator for the Shop Floor Reporting and act as trainer for all users.

Lead and manage the variance team in production.

Manage disciplinary problems among associates.

Educate line team to use 7 QC tools in problem solving.

Achievements:

Developed and trained new users on SAP MM/PP version 4.9. Completed the upgrade training for all relevant manufacturing users and achieved 85% success rate.

Developed 8 TPM line teams and managed to improve the OEE from 55% to 65% via team activities and reducing downtime via maintenance.

Trained 6 operators and successfully reduced the changeover on pilot line from 4 hours to 2 hours via SMED techniques

Trained all team leaders on data analysis and utilization for downtime improvement and managed to reduce overall downtime by 30%

Implemented weekly stock count posting in SAP and variance investigation resulting in variance reduction and achieving better that budgeted variance by year end.

Developed the team leader weekly meeting session to handle common process for discipline issues among associates resulting in standard process by all team leaders.

Teams trained on how to use the tools and enable downtime analysis by operators and resulted in improvement of OEE for target project lines.

.

Minolta Precision Engineering (M) Sdn Bhd ( Japanese MNC )

Position Title : Assistant Manager - R & D Duration: Apr 1991 - Sep 1998

Responsibilities:

Planning and Scheduling of new product transfer on optics field.

Planning and conducting of Training for Engineers on optics.

Trainer for product and machine optical problem troubleshooting.

Product Technical documentation and ISO controller.

Machine software (Z80 Assembler) modification and development.

Troubleshooting machine and maintenance in clean room environment.

Attend training in Japan for new product transfer to Malaysia.

Maintain and develop the Kanban production system.

Train and lead the SGIA teams in production.

Identify cost reduction by implementing tools control system.

Identify department training needs and conduct training.

Develop camera checking machine software and design of jigs.

Develop and set up a new manufacturing engineering department.

Develop and lead all teams on Kaizen activity and process improvement implementation.

Identify and implement line process and layout improvement via time study and process analysis.

Maintain and troubleshoot product optical problems in the line and in clean room assembly area.

Developed technical trouble shooting manual for training and education on product optical problems.

Manage the optical group projects and developing the optical team to become independent and knowledgeable.

Achievements:

Successfully transferred various new products from Japan resulting in cost reduction and more project transfers to Malaysia.

Trained 4 fresh engineers to the level of able to trouble shoot and handle optical issue on their own.

Conducted technical training for all technicians, engineers and sub contractor technicians enabling faster problem solving and improvement on technical knowledge for all levels.

Conducted internal audits and developed new procedures for R & D departments enabling ISO9002 certification.

Developed and modified machine Z80 software from Japan to enable local machine software development and machine modification done successfully.

Developed and implement new checking software and jigs on the production line.

Set up a new department with fresh technicians and managed to be fully functional in 3 months time.

Implemented line improvement project which reduced the changeover crew by 6 people and reduced the cost by RM150,000 per year via time study, process analysis, manpower relocation and line layout improvement.

Relocated the press line and unpacking layout to improve space utilization and production process flow, which allowed less movement of parts from the machining to the finishing line and reduced quality issues.

Managed the kanban system for the whole production processes and developed new card management system to avoid parts shortage and wrong parts placement.

Developed an online tools inventory and ordering system managed by MS Access leading to tools cost saving of RM100,000 for the 1st. year of the implementation.

Conducted training for fabrication process and kanban system maintenance and line improvement projects, which allowed technicians to carry out and implement projects independently. Also lead the SGIA team to successful completion of the cost down projects.

Languages

Language

Spoken

Written

Bahasa Malaysia

Good

Good

English

Good

Good

Bahasa Indonesia

Fair

Fair

Tamil

Good

Chinese

Poor

Japanese

Poor

Additional Info

Willing to Travel : Yes Willing to Relocate : Yes

Possess Own Transport : Yes Availability : Immediate

Awards:

Minolta : (1)SGIA - 3rd place Minolta :(2) Kaizen Excellent Achievement award

Colgate Palmolive : (1)SMED Changeover reduction – TPM team development

Goemar Labs. De La Mer (France) : Letter of Recommendation from Packaging Mgr

Personal Strengths:

Have strong will to improve oneself and team, utilizing continuous education and training.

Team leadership capability, Downtime analysis, Cost saving, Problem solving

Highly Adaptive, Experienced in Diversified Culture and strong management empowerment

Very flexible and have vast experience in various working conditions, processes and environments and working with different levels of subordinates and superiors

Highly disciplined and safety conscious and Top priority in all work concern.

A very hands on person and able to handle machine/facility equipments,, troubleshooting and training new technicians/engineers, developing SOP/Manuals, conducting training and on job assessments.

Very good with numbers, statistics, analysis, finance management and inventory control.

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