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Operations, Manufacturing, Quality Assurance, Six Sigma

Chennai, Tamil Nadu, India
October 05, 2016

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Anbalagan Kathiresan, E-mail:

**/*, **.********* ***** Extension, Mobile: +91-955*******

Thiruvanmiyur, Chennai-600041.India. Skype: anbu67

Aiming for Senior Managerial Position to head the Plant Operations with

P&L Responsibility in a reputed Engineering Industry

Professional Summary

Over 26 years’ experience in Strategic Planning, Manufacturing Operations, Systems Reengineering, Process Management and Quality Management with reputed organisations in India and Overseas, including 5 years experience as Profit Center Head with Profit and Loss Responsibilities, New Product Development, Product Costing & Supply Chain Management.

Skilled in Design, Development and management of Robust Processes & Methods and procured new machineries for achieving Productivity enhancement as well as reduction in Rejection Levels & Costs.

Well-versed with Quality Management approaches like Lean Practices, 5-S, Kaizen, Quality Circles, TPM and Six Sigma Black Belt Certified Professional.

Successfully implemented the Green Field Project of MPVC Pipes, Foam Core Pipes, Electrical Corrugated Conduits and PVC Casing & Capping products as well as Brown Field Projects of Poly Ethylene & UPVC Pipes with accreditation of AS/NZS (Australian/New Zealand) Product Standards, ISO 9000 and OHS Standards.

An Effective Communicator with Strong Leadership, People Management, Industrial Relations & Union Handling, Coordination, Interpersonal Skills and Analytical Skills.

Career Scan

Southern Pressure Casting, Chennai as Plant Head (Apr’13 Onwards)

(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 within 3 years time.

Process Improvements in Foundry operations through Continuous Process Parameters Monitoring.

Developing Systems in Shop Floor and allied areas as well as Safety systems in shop floor.

Productivity Improvements in CNC Machine operation through Cycle Time Reduction with the help of EdgeCam Software and Value Stream Mapping.

Training of Employees and staffs for 5S, Kaizen, QC Tools etc.

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.

Initiating and guiding of Lean Improvement project 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.

Passion and Commitment of achieving Targets as per Budget Norms & 100% in Customer Satisfaction.

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.

Desired Quality of the plant operations was achieved through Implementation of Six Sigma Black Belt Projects, Lean Improvements, Business Process Re-engineering, Productivity Improvements, 5S, TPM, Process Safety & Hazard Analysis, Safety Audits and grooming of Team members on the shop floor.

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 in the planning and 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.

On taking up the assignment, was instrumental in setting up a New PE Pipe Plant to manufacture Polyethylene Pipes with Colour stripes, to commence in Fiji thereby avoiding 80% imports of pipes from Australia & New Zealand.

Subsequently was responsible for setting up a plant to manufacture MPVC pipes and successfully installed with accreditation by the AS/NZS product standards.

Setup new Factory through adding new pipe plants with modernisation of existing UPVC pipe plants and by procuring new plant accessories as well as raw materials.

Export of UPVC, PE, MPVC pipes to New Zealand and the nearby islands was a big endorsement to our capabilities. Over the years at Tubemakers, have the pleasure of improving the revenue from $6 million at the time of joining to $15 million through Turnaround Management & Strategic initiatives like introduction of new products and slew of measures which encompassed Quality Assurance, AS/NZS Product Standard Implementation, Customer Satisfaction, Cost Reduction, Cost Control, Factory efficiency, Implementation of OHS standards, Facilitate Group Building, Group Problem Solving & Decision making through cross functional knowledge and networking.

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) (Apr’03 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.

Instrumental in achieving high degree of customer satisfaction by 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.

Handled successfully Wage settlement with Union.

Bright Brothers Limited, Pondicherry, India as Manager (Operations) (Jun’01 to Mar’03)

(A QS 9000 Certified company & manufacturer of Plastic Injection Moulding Components & Plastic Blow Moulding Components for OEMs in the Automobile & Consumer Durables Industries)

Responsible for Production Planning, Quality Assurance and Maintenance.

The role required regular interaction with Purchase, Commercial, Stores, Accounts and Human Resources to ensure targets were achieved.

Ensuring Compliance to Quality Standards was supplemented by my initiatives to add value in Quality Improvement, Value Engineering, Productivity Improvement and Cost Reduction.

Played key role in the implementation of Just In Time concept & OEE Calculations.

Succeeded in achieving 100 ppm in Hyundai, Hanil Lear & Indrad Auto components; and Zero Percent Rejection in Alavanci model lid assembly.

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.

Ensuring Compliance to Quality Standards was supplemented by my initiatives to add value in Quality Improvement, Value Engineering, Productivity Improvement and Cost Reduction.

Pivotal in the implementation of cost reduction measures in 3 layer film plants and achieved Rs. 2450 per plant.

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.

Was responsible for Production of Bicycle assembly manufacturing. This involved leading Teams, Managing Resources, training them, ensuring Quality Objectives were met and the regular upkeep of whatever that went into the timely Production of the Assembly Manufacturing.

Performing this role required working pro-actively with teams and aligning with the Mission and Vision of the organization to achieve the stated Objectives of the Organization.

●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)

Inducted as a Management Trainee and Promoted as Production Engineer in Relay Feeder Assembly Production. Hands on approach over five years ensured that I learned the fundamentals of Production, Planning and Control as well as Latest Manufacturing Techniques.

In addition I was involved in designing of New Jigs, Tools and Fixtures for Relay Feeder Assembly.

Earned the respect of stakeholders by delivering all aspects relating to my key result areas in a timely manner through Latest management Concepts, Quality & Productivity Improvements.

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%.

Academic Credentials

MBA (Finance) from Indira Gandhi National Open University, New Delhi, India 2016.

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

Lean Practice

OHS Modules 1 to 6

Factory Act

JIT & Kaizen


Safety Audit

Computer Proficiency

SAP Business One

Minitab 16

MS Office



Personal Dossier

49 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).


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