MANOJ.K.R

acyj49@r.postjobfree.com

****, ********** ******

Maryville, TN 37801

Summary Of Skills

Industrial Engineer/Manufacturing Engineer with strong base in Process Engineering, Problem Solving, Trouble shooting of Machines, Process complimented by effective interpersonal skill, organizational ability & ability to communicate in Japanese.

Education

Diploma In Mechanical Engineering June 87

Dept. Of Technical Education, Kerala, India

Work Experience

JTEKT Automotive,Vonore TN Jun 2014 Onwards,

Manufacturing Engineer- Machining & Assembly Line- Hydraulic Power Steering

.Involved in Machining Line relocation,completion of Capability study.

.Launched New Products in Machining Line.

.Replaced the Old Machining Center, with Reconditioned machine and done Capability study for different types of Steering Parts.

.Reduced the changeover time CNC Machining Line, by re designing the Fixtures.

.Process improvement,in line with Production requirement.

.Identifying and Resolving Bottle neck Operation & Methods .

.Identifying the areas for Cycle Time reduction and effective implementation.

.Introduction of new Tooling to reduce Cycle Time, reduce cost / piece .

.Supporting Maintenance in Machine Break downs and Start Ups.

.Creating/ updating Process Sheets, PFMEA .

.Supporting Manufacturing & Kaizen Teams,in problem solving, improvements.

JTEKT Automotive, Ennis TX Dec 2012 –May 2014.

Manufacturing Engineer- Intermediate Shaft Line ( Bolt Yoke Machining Lines

& Intermediate Shaft assembly Line).

Involved in, Machine Installation, ITO, TTO.

Independently Completed the Capability Studies for Bolt Yoke Machining Line, which were not completed during ITO/TTO.

Modified/ Changed, Bolt Yoke Machining line, tooling and completed HVPT trials.

Modified / Improved the Assembly line machines and completed HVPT trials. Reduced the Bolt Yoke Machining Cost – brought down the cost by more than 50%,Which resulted in saving $ 950,000/ year .

Reduction in Bolt Yoke Machining time.

Identifying the problem areas and implementing the counter measure, which resulted in

Improved Bekido(efficiency) & Chokko(rej/scrap reduction) . With continuous improvement process, reduced the Assembly Line Cycle Time, from 39 sec to 34 sec.

Localization of Tooling, Machine Spare parts, which resulted in cost saving as well as Inventory reduction .

Training Team leaders, Resources, to improve the Bekkido, Chokko. Coordination with JTEKT,Japan and JTEKT JAPAN Advisors, on Machine/ Process issues.

Supporting Maintenance in Machine Break downs and Start Ups. Creating/ updating Process Sheets, PFMEA .

Komatsu NTC Ltd, Toyama Japan (Machine Center Division) From Dec1999- Nov 2012.

Industrial Engineer & Service Manager (Overseas Market) Coordination with Engineering Dept & Assembly Dept during Machine Building.

Design Evaluation Of Fixture, tooling s, Process.

Inspection & Testing of Fixtures, during manufacturing. Coordinating & Supervising the Final assembly of various Machine elements& Testing.

Preparing the Machine/ Complete Line for Process Capability Study prior to Customer Inspection.

Coordinating the Run off & Capability study along with Customer. Preparing the Trials Reports, Follow up, Implementing Corrective action. Installing the Machine/ Line at Customer Plant, proving the process and establishing the committed product & process quality. Imparting training to Customer, related to Machine operation, Trouble Shooting techniques, adjustments of machines and adjustments of process parameters.

Providing Pre sales & after Sales Support to Service Centers and to Customers.

Coordinating with Service Engineers and internally, on various service issues.

Organizing and Conducting Training to Service Engineers & Customer's Engineers Preparation of process sheets and Cycle time. Projects Handled In Komatsu NTC Japan:

Sr No Project Details Customer Remarks

1 Valve Body

Machining Line.

Machine:

Horizontal

Machining

Center ( Taper

#40)

Allison

Transmission,

USA

Handled

Independently

the Project.

2 Cylinder Block

(2 Cylinder)

Machining Line.

Machine:

Horizontal

Machining

Centers (Taper

# 40 &# 50)

Tata Motors India Handled

Independently

the Project during

Run off at Japan

and during

Installation.

3 Cylinder Block ( 4

Cylinder) Finish

Machining.

Machine :Horizon

tal Machining

Centers ( Taper #

50)

Mahindra &

Mahindra

India

Handled

Independently

the Project during

Run off at Japan

and during

Installation

4 Cylinder Head ( 2

Cylinder) Finish

Machining.

Machine:

Horizontal

Machining

Centers

(Including Valve

Finishing)

Tata Motors India Handled

Independently

the Project during

Run off at Japan

and during

Installation.

5 Cylinder Head (4

& 6 Cylinder)

Machining Line.

Machine:

Horizontal

Machining

Centers (Taper

#50)

Tata Motors India Handled

Independently

the Project during

Run off at Japan

and during

Installation.

6 Transmission

Case Machining.

Machine:

Horizontal

Machining

Centers (Taper

#40)

Suzuki

Powertrain India

Handled

Independently

the Project during

Run off at Japan

and during

Installation.

7 Gear –Pinion

Machine; Vertical

Machining

Center (Taper

#40)

Mino Precision,

Japan (For

Nissan

China)

Handled

Independently

the Project during

Run off at Japan.

8 Crankshaft-

Centering & Oil

Hole

Drilling.Horizonta

l Machining

Centers ( Taper

#40)

Kia Motors, South

Korea

Handled

Independently

the Project during

Run off at Japan.

9 Clutch Housing &

Gear Box

Machining Line.

Horizontal

Machining

Centers (Taper

#40)

Renault Nissan

India.

Handled

Independently

the Project during

Run Off at Japan

and during

Installation.

10 Differential Case

–Machining Line.

Machine :

Horizontal

Machining

Centers

(Taper#40 & 50 )

Yutaka Japan Handled

Independently

the

Project,during

Run Off and

Installation.

11 Differential Case

– Finish

Machining.

Machine:

Horizontal

Machining

Center (Taper

#40)

Mahindra &

Mahindra India

Handled

Independently

the

Project,during

Run Off and

Installation.

Training Undergone:

Sr No Course Duration Contents

1 Introduction to

Modern Cutting

Tools.

Sandik Asia,

Pune, India.

1 Week

March 1994

Tool Selection

Criteria, Cutting

Parameters

selection,

Introduction

To New

Technologies.

2 Introduction to

TPM

Productivity

Council, Mumbai

India

3 days

May 1995

Introduction to

TPM, 5S

3 Advance Training

In Machine Tools.

Heller GmbH,

Stuttgart

Germany

3 Weeks

September 1996

Operation,

Programming,

Trouble

Shooting of

Horizontal

Machining

Centers.

4 Advance Training

In Machine Tools.

Stama GmbH,

Stuttgart

Germany

2 Weeks

Sept/ Oct 1996

5 Weeks

April/ May 1999

Operation,

Programming,

Trouble

Shooting of

Vertical

Machining

Centers.

Spindle

Assembly,

Testing &

Repairing

5 Advance Training

In Machine Tools.

Nippei Toyama

Corp, Toyama

Japan

3 weeks

April 1998

Operation,

Programming,

Trouble

Shooting of

Horizontal

Machining

Centers, Vertical

Machining

Centers.

6 Advance Training

In Machine Tools.

Muratec, Aichi

Japan

1 Week

May 1998

Training on

Turning Centers

& Mill Turn

Centers.

7 Advance Training

In Machine Tools.

Ikegai

Corporation,

Tokyo Japan

2 Weeks

May 1998

Operation,

Programming,

Trouble

Shooting of

Horizontal

Machining

Centers, Vertical

Machining

Centers, Turning

Centers, Mill Turn

Centers.

8 Introduction to

Self Feeders &

Drill Tap Centers.

Sugino Machine,

Singapore

3 days

May 1998

Operation,

Programming,

Trouble

Shooting of Drill

Tap Centers,

Self-Feeders.

Others:

Have a good working Knowledge in Solid Works,MS Excel, Word etc.

Contact this candidate