Manager molding

P. SENTHIL KUMAR

SNAPSHOT

** ***** ** ********** ** the areas of Plastic injection moulding Process & Manufacturing Engineering

Sound understanding on Plastic Process Engineering, Production Operations, Project Management and New Product Development.

Presently associated with Varroc Lighting Systems as MANAGER – Injection Moulding Production

Six Sigma Green belt certification holder from MSME Central govt India, handling multiple green Belt level projects.

Responsible for Initiative of Development activities of Manufacturing Cost cut down.

Responsible for the Smooth Operation of Factory from Customer Order to Delivery.

Skilled in process improvement projects with respect to cost, resource deployment, time over-runs and quality compliance; evaluating project progress & taking adequate corrective actions.

Acquired exposure in handling various types of Molding machines

Plastics material handled PET, PBT, Nylon, PP, ABS, HIPS, PMMA, Delrin, HDPE, PC+ABS, PVC.

Proficient Knowledge in various Plastic conversion techniques like Injection moulding, Extrusion Blow moulding Stretch Blow Moulding, Gas assisted Injection moulding, Insert Moulding, In-mould Decoration, Thermoforming, Extrusion moulding,Sputtering,Ultrasonic Welding,hot plate welding etc.

Ability background of handling project Engineer team with assignment of task, resource assignments, follow of task, review techniques and report making.

Worked in moulding machine range from 90 T to 1500 T

Having Exposure of 3 axis / 6 axis Robot.

Sufficient knowledge in VSM, SPC, MSA, PPAP&APQP.

Handled Audits of 5 STAR, ISO14000 & TS 16949.

Having capability of leading Lean & six sigma Projects.

CAREER CONTOUR

Varroc Lighting Systems as Manager – Injection Moulding Production

Since July 2015 (1Year 2 Months)

Varroc lighting systems global manufacturer of Automotive Lighting systems

Supplying parts to Volkswagen, Mahindra and Mahindra, General Motors Ltd, Tata Motors, Volvo, etc .

Roles and Responsibilities

Head of Moulding Production

Ensure smooth operations of Production to support customer line on PQCDMS

To plan and lead process improvement initiatives on implementing LEAN MANUFACTURING SYSTEM (KANBAN, ANDON, SMED, VSM, LPA).

Accomplishments

Layout management – Modified Layout and reduced movement of Material and Moulded part movement

KAIZEN – educate all level of employees to involve in KAIZEN activity and increased number of KAIZEN’s implemented

Implemented ANDON system to improve real-time communication between Moulding, Tool room and Maintenance and reduced downtime (and in turn increased Availability factor by 7 %)

SMED-Reduced no of mould change over calculating Optimum Batch size of mould loading

SMED -Introduced POKA YOKE in mould cooling water IN/OUT piping and Core IN/OUT

SMED-Implemented QMC system for mould change over to

Introduced daily top 5 defect analysis and reduced rejection root causes

OEE –continues monitoring of Machine utilisation by Hourly output monitoring.

OEE- Robot implementation in 7 critical machine to improve cycle time (Performance factor).

OEE – Mould OFFLINE preparation to reduce setup time and mould change over time.

SL Lumax India as Deputy Manager – Injection Molding Production

Since May 2009 to July 2015 (6 yrs. 2 months)

SL Lumax ltd is the worldwide largest manufacturing unit of automotive Parts like Head Lamp and Tail lamp, Mirror, Chassis assemblies and Precision plastic injection molded parts.

Supplying parts to Hyundai Motor India ltd, General Motor India ltd & Ford India ltd.

Roles and Responsibilities

Major Responsibilities / Management assignments from the Organization(KPI)

oAchieve Production Mark up 95 % and Sustain

oAchieve Rolled Through put Yield 87 % and Sustain.

oSuccessfully Implement JIT Production System with KANBAN.

oLead a LEAN TFT team and reduce the rejection of 50 %

Head of Lamp Moulding Plant to Organizing,Leading and Achieve Production related KPI

Complete follow up of Customer Order status from Moulding, Coating and Assy.

Handling a Group of 75 Team Members, which includes Foreman, Engineers and Operators.

Accomplishments

Successfully implemented JIT through Child parts Kitting Mechanism and D+2 WIP system ( KANBAN SYSTEM )

Achieved Production Mark up 97 % through

1.Rejection Reduction –Through Six Sigma Projects

2.Mould Change Over Time Reduction( from 60 min to 30 min) -by Time Study and Motion Study and Quick Change over techniques ( SMED )

3.Operator and Engineer Training by Providing Scheduled Training Programs and Defect Knowledge Bank.

4.Formed a TFT with HR dept and given training with the title of Basic Professionals Training for Engineers.

Achieve Rolled Through Put Yield 90 % through

5.Six Sigma Projects.

6.Moulding Cycle Time reduction by Cycle compression technique in Pick & Place robot and Robot Jig Modification.

7.Coating UPH improved by Sputtering Jig modification.

8.Introduced Simple Automation Techniques to Reduce Man Intervention and Ensuring Fool Proofing.

Jabil Circuits India Pvt. Ltd., as Process Engineer for Injection Moulding- IMD (In-Mould decorative)

Mar ‘06 to April 09 (3 yrs – 1 Month)

One of the Moulder for Nokia Mobile Phones, Moulding Mobile phone Parts

Roles and Responsibilities

In charge of Process Engineering team with the responsibility of Yield, Efficiency and OEE.

Providing required support to the organisation as Cross Functional Team member.

Carrying out production schedule as projected by marketing department and PPC resulting in smooth production.

Identifying the problematic areas in mould, machine and component and taking suitable remedies for the problems using problem-solving techniques.

Submitting reports to top management as a MIS coordinator on plant OEE, KPI data, Yield and efficiency trend, rejection analysis through 80/20 principles, machine performance, raw material reconciliation & continuous improvement projects.

Accomplishments

Adeptly carried out various machine capability, process capabilities, and mould & material trials.

Instrumental in implementing a methodical approach to reduce cycle time of the product with the help of Process Optimization techniques.

Deftly conducted the mould / material tryouts and using Poke Yoke on required functional areas.

Pivotal in the carrying out the installations and improving the IMD clean room shop floor.

Worked towards increasing the yield and efficiency by analysing effect with dust particles counter report in the clean room.

Substantially minimised:

The rejection rates using the process optimization techniques.

Product change over time by adopting the systems of Kaizen and Poke Yoke.

Distinction of saving costs through:

oDent Level Reduction Projects, which saved $ 4300 in 5 months.

oMTC reduction in IMD tools up to $ 4500/ year.

Key role in imparting professional training to:

oThe Ukraine Engineers for their new IMD Project.

oChennai Engineers for their new IMD Project.

Played a Key role in New product development activities for HANOI project in Shenzhen ( China )

Credit of improved the Yield from 92 % to 98 % in short while.

Futura Preforms Limited, as Moulding Technician

Dec 2001 to Feb 2006 (4 yrs. – 3 month)

One of the PET bottle manufacturers for leading soft drinks

Roles and Responsibilities

Worked as Process technician in Preforms Moulding up to 500 T

Taking trial of New developed materials from our in-house resin manufacturing division

Optimising process Parameters and reporting the feedbacks

Blow mould the preforms and Optimizing the Parameters

Submitting Trial Report to R & D department

Development activities in Process Improvements

Accomplishments

Played a vital role in incrementing the overall productivity through effective tooling and improvement methods.

Successfully reduced the costs by implementing a waste recovery system

Contributed effectively in carrying out cycle time optimisation by trend line monitoring, product quality follow-up & raw material condition monitoring.

Adeptly deployed 5S good housekeeping habits and maintained discipline in the production line.

Effectively conducted a follow-up of the losses and implemented corrective and preventive actions.

Deftly implemented kaizen & provided suggestions for production improvement.

ACADEMIA

2001 Diploma in Mechanical Engineering from Sri Sai Ram Polytechnic, Chennai, Tamil Nadu;

Secured 92.75% with first class

2009 B.Tech. Production Technology-from Anna University, Chennai, Tamil Nadu, India.

SKILLS IN COMPUTER

Application and Tools :

MS Office (MS WORD, MS EXCEL, MS POWERPOINT& OUT LOOK), MS Projects, MS Visio, Auto CAD, Catia V5, Mini Tab 15 and Macromedia Flash

PERSONAL DOSSIER

Date of Birth : 6th April 1981

Languages Known : Tamil, Hindi and English

Passport No : Available (Valid)

E-Mail : *********@*****.***

Contact no. : 91-738*******

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