JAYAPANDIYAN. G

E-mail : ad3iw2@r.postjobfree.com, ad3iw2@r.postjobfree.com

Contact : +91-890******* / 958-***-****

LinkedIn: -https://www.linkedin.com/in/jayapandiyan-g-869a8237

MANAGEMENT PROFESSIONAL – MANAGER MANUFACTURING

Targeting Assignments In:

Production /Machining & Assembly Line Operations TPM secretary Production Planning & Control Process & Quality Improvement Engine Assembly & Testing, Farming Assembly and Vehicle Testing

Successfully lead Production Operations while working in technically advanced, state-of the-art plants in the Automobile industry with key focus on optimum utilization of recourses such as man, machine, material & budgets (opex)

PROFILE SUMMARY

BE - Mechanical offering over 20 years of rich experience in:

Project Management, TPM secretary, Production Planning & Control, Engine Parts Manufacturing & Assembly, Farming Vehicle Assembly & Testing Process Improvement/ Cost Savings, Ceramic Production, Weld assembly Shop, Disc break pad Manufacturing, EMS, ISO, TS & OHSAS Compliances, Quality & Safety Assurance Wastage / Scrap Reduction, OEE / Testing / Problem Solving, Manpower Management/Trainings, Material / Inventory Management, PFC, SOP, Control Plan, PFMEA, PPAP VAVE, Farm Vehicle PDI (2.5 HP to 18 HP), TPM, TQM

●Presently Associated with MURUGAPPA MORGAN THERMAL CERAMICS INDIA LIMITED as Manger Production Incharge - Ceramics blanket, shapes production as per customer requirements by using artificial ceramic fiber. Continuous process (Furnace), Engineer fiber, vacuum forming of ceramic shapes. PQCDSM Improvement, achieved 50 lacs cost savings per month in various KPIs. New product Production line creation, Motivation all Production manpower by daily interaction. Meeting customer demand. MIS preparation for Morgan, Product cost fixing, Safety first culture following (Morgan).

●Previously with L G Balakrishnan & Bros (LGB) as Manager Projects (Engine Assembly Project Head), Heading Engine assembly Project, capacity planning as per customer demand. Manufacturing infrastructure development as per capacity required. Customer coordination, project timeline planning up to PPAP and SOP, Manpower management, Coordination with supplier and intercompany teams, Project execution. Successfully achieved SOP and got appreciation from customers, project status update and reporting to MD

●Previously associated with RANE BRAKE LINING LIMITED as Assistant Manager – Production.

●Career Started with GREAVES COTTON LIMITED from Apprentice to Assistant manager operations excellence. Skilled reduce Cost of Manufacturing by reducing waste generation, excess usage, visual management, and value analysis, also bench mark the outcome towards excellence through TPM implementation (from Kick of to Health checkup). Experienced in JH Level 4, QM, KK, PM, E&T, SHE, OTPM, DM. Rich and Hands on experience in Union (7 – Types of Union) settlements negotiation and issues salvations.

●Drove TPM Circles, Pillars, Opex (Operation Expenditure) & Continuous Improvement initiatives like 8-Pillars of TPM, 5S, FMEA, Production Control Plan, 7 QC Tools, Kaizen, Lean Manufacturing, VSM (Value stream mapping) OPM (Opportunistic maintenances) on the shop floor to achieve smooth production operations, time & cost savings. Pivotal in ensuring compliance as per ISO/TS 16949 standards & maintaining necessary documentation with strong knowledge of IMS (Integrated Management System) including EMS & QMS, ISO 14001 & 18000 OHSAS for Safety & Hygiene.

●Rich exposure to TPM Implementation and Practices and Manufacturing of Ceramic products, Door Frames, Single Cylinder Diesel engine from 2.5 HP to 18 HP, Farming Vehicles with technical expertise in:

oTPM methodology and approach to Achieve KPI parameters among the Pillars and circles.

oEngine Assembly, Engine Testing, Vehicle Assembly and Testing from Project to SOP and productivity improvement.

oHad Training and operating CNC machines like VMC (AMS), HMC (BFW), NTC, Mazak and also have operating experience.

Gear hobbing (HMT), Gear Shaving (Russian), Hardening (Inductotherm, Inducto heat), Tempering, annealing, lapping, Grinding (HMT, TOYODA), Cylinder barrel Honing (Nagel).

Notable Accomplishments across the Career

●Effectively implemented cost / energy saving & process improvement measures and recorded key achievements like:

oKBI, KMI, KPI, KAI target fixing and achievements among all Pillars and circles.

oProduction Planning Hourly, Daily, Weekly, Fortnightly Monthly based capacity updates and cycle time, other factors... Machine Uptime (Crank case, Cy. head, block) increased from 85% to 90 % and Bottleneck machines Uptime increased from 84% to 87%.

oAchieved vehicle assembly output 30 Nos from 20 Nos for 15DIL power tiller by Value stream mapping year 2018

oIncreased 5s score from 40 to 60 throughout the plant by introducing RED Tag area for disposal of unwanted, framing customized check sheet & improving material handling from raw material store to Engine assembly year 2017.

oImproved machine JH score from 30% to 70% for all 80 machines throughout machine shop, increased OEE 85% from 70% by capturing major losses and resolving them and Engine assembly OLE 95% from 90% - year 2017.

oImproved machine JH score from 30% to 70% for all 80 machines throughout machine shop, increased OEE 85% from 70% by capturing major losses and resolving them and Engine assembly OLE 95% from 90% - year 2017.

oReduced set-up changeover time by 30% from existing time Engine testing by using Quick changeover technique & SMED.

o Waste Elimination done by using Lean Manufacturing Systems

oReduction in Material cost of Machining Lines from 25 INR to 15 INR per Engine through VAVE

oEngine Assembly Uptime increased from 87% to 95%; improved in Engine Assembly Line

oAchieved highest production target by increasing Availability Rate and De-Bottle Necking the Disc pad Manufacturing process.

oAchieved highest production target at Grinding cell by capacity improvement by implementing LCA and bed space utilization increased by locator pin modified.

oIncreased productivity by Designing crusher type dresser for crank shaft, crank pin grinding operation. (Dressing Time Reduction).

oIncreased productivity by heating coil setting time reduction for hardening process.

oReduced rejection at crank shaft line on keyway milling operation by designing depth adjustment attachment.

oIncreased production at Engine testing from 09 to 12 by waste eliminating.

oIncreased production 10% at Engine testing by Eliminating NVA and Over lapping Activities.

oIncreased productivity 10% at Engine Assembly by Line Balancing.

oReduced from 6 PDI conveyor stages to 4 stages by ECRSAP method.

oReduced from 29 engine assembly conveyor stages to 26 stages by implementing low-cost automation &ECRSAP method (Stages Reduced from 29 to 26 Stages)

●Successfully executed key projects like:

oVAVE (Value Analysis and Value Engineering) Project for cost saving in Disc pad packing of cotton box 0.85 paise per cotton in 2018.

oVAVE (Value Analysis and Value Engineering) Project for cost saving in material Rs. 200 per Engine in 2016 to 2018

oVAVE (Value Analysis and Value Engineering) Project for Consumable cost saving in Engine testing Rs.20 per Engine in 2014 to 2016

oOPEX (Operation Excellence) Project resulting in Waste Elimination & Indirect material cost reduction.

●Facilitated Problem Solving by using TPM Circle Tools & QM pillar, Seven Steps: effective resolved issues of:

oEliminated leakage of oil from crank shaft through oil seal in MK series engines during testing, issue resolved by changing material of oil seal from nitrile to Polyacrylic with hydrodynamic design, which can with stand temperature range from 120 C to 140 C year 2018.

oPulley Bolt Torque Not Ok issue for improving Quality & Uptime in Engine Assembly Line

oEngine Red flame and High smoke problem corrected in Engine assembly by changing method of Static injection timing checking.

oSupport to resolving abnormal noise of engine with engineering team for reduces warranty issue.

WORK EXPERIENCE

Since Sep’22: MURUGAPPA MORGAN THERMAL CERAMICS INDIA PVT LTD., Ranipet. Tamil Nadu as Manager (Manufacturing) – Heading Overall production operations.

●Leading a team of 120 members of an age group of 20-58 years to meet timely production targets with required quality & safety

Job Responsibilities:

oDrive managers for initial cleaning daily in the select machines during Jishu Hozen time (JH) and educate operator to maintain the same after cleaning.

oMake the operators to identify abnormalities by tagging and support them to resolve within the time frame. White tag for solving on own and red tag for solving with the guidance of experts like maintenance and tool room. Improving and achieving White Tag Removal rate 85% by motivating and support shop floor operaters.

oCreate owner ship culture down the level by education and training, thereby demonstrate "I operate I maintain".

oReduce fiber exposure by continuous monitoring and eliminating SOC at furnace and supporting and facilitate circle leader's to change HTA to ETA.

oEnsuring CLITA charts updated by Circle leaders. To reduce downtime every pillar meeting CLITA standards revised with PM and JH pillar chairman.Ensuring Circle meetings and MOM will done by Circle leaders.

oEnsuring KK loss capturing will be done by Circle leaders. Improving OEE from 80% to 90 % by loss elimination. Reduced annealing power cost through cost tree methodology

oImprovement productivity from 13.5 to 15 MT / day by eliminating Speed loss.

oReduced rejection from 15 to 10 % by deriving 4M condition, QM matrix, PM analysis and FMEA through Quality PM pillar & reached defect occurrences in single digit.

oDrive the circle leaders and members to achieve ZERO Breakdown, ZERO Accident and ZERO defect in Furnace, Vaccum forming, Engineering fibre, modules making cells. Also facilitate education and training program for new comers through E&T pillar.

oAchieved Mean time between failures (MTBF) > 20 days from 17 days and Mean time taken to repair (MTTR) < 1 hr from 4 hr throughout furnace floor through planned maintenance.

oCreate owner ship culture down the level by education and training, thereby demonstrate "I operate I maintain".

oReduced FG inventory from 25 days to 7 days by introducing customer priority based production planning and work order creation (in JDE) system through OTPM by using material information flow methodology and Eliminated over production waste.

oAchieve Zero accident and near miss in single digit through safety, health and environmental pillar.

oHeading KK pillar and driving JH, KK, QM, E&T in all over plant as production incharge.

oPreparing monthly production plan based on the customer orders. Preparing day wise production schedule based on the priority.

oGenerating material shortage list for the month and ensuring availability of raw material.

oControl of manpower and machine utilization. Concentrating on production to meet daily asking rate.

oResponsible for Adherence of production plan. Forecast analysis, Budgeting, and annual operating process.

oRejection analysis and making projects to reduce rejections.

oNew product development in co- ordination. Creation of Bill of Materials (BOM) for new products.

Coordination With:

oMarketing team for getting customer orders placements.

oPurchase team for ensuring availability of materials. Logistics team for on-time delivery.

oQuality assurance to fulfill the customer with delighted in process and incoming quality.

oCoordinate with NPD & R&D team for new products developments and trials.

oAnalyzing RM shortage for next month’s production with the co-ordination of purchase team.

o daily production target with the co-ordination of manufacturing unit.

Mar’20 to Sep’22: L G BALAKRISHNAN & BROS. LIMITED, Coimbatore. Tamil Nadu as Deputy Manager (Project Head) – Heading Engine Assembly Project

Job Responsibilities:

oContractual agreement verification with legal team.

oLiability Insurance follow-up with corporate finance and marketing team.

oProject Investment estimation preparation and getting approval from LGB and Customers.

oProject timeline preparation.

oCapacity determination as per customer demand.

oLayout preparation as per capacity plan

oEquipment’s and tools designing, planning and execution as per capacity plan.

oSupplier selection and price negotiation as per project investment plan.

oProject expenses monitoring and controlling.

oProject execution team recruitment as per budgeted plan.

oNew team training and evaluation.

oSpecial equipment’s close follow-up with supplier.

oPFC, PFMEA, Control plan, PPAP, SOP documents preparation.

Coordination With:

oMarketing team customers related issues.

oPurchase team for ensuring availability of 4M and Logistics team for on time delivery.

oQuality assurance to fulfill the customer with delighted in process and incoming quality of child parts.

oIntermediate customer HINDUJA TECH for engine assembly related design issues.

Achievement:

oSuccessfully started SOP as per timeline.

oGot appreciation from customers (WIDESCAPE, HINDUJA TECH) for success of SOP without NC.

oGot appreciation from LGB management and customers for investment profit 2 cr.

Nov’18 - Mar’20: Rane brake Lining Limited, Chennai as Assistant Manager – Manufacturing

Key Result Areas:

●Lead the team of 180-200 members including Supervisors & Team Leaders of an age group of 20-50 years for managing Disc Pad Manufacturing Cells as Assistant manager in production and In-process quality department.

●Managed the Production and Inprocess quality of Curing, Backing, Painting, grinding (Finishing), Packing.

●Controlling absenteeism & doing proactive leave planning as per absenteeism coverage provided

●Resolving IR issues & manpower issues by doing counseling with team members

Dec’2004 - Nov’2018: Greaves Cotton Limited, Ranipet. Tamilnadu. as Assistant Manager (Manufacturing)) – Operations – Career Path Follows

April’14 - Nov’18: Greaves Cotton Limited, Ranipet. Tamilnadu. as Assistant Manager (Manufacturing) – Operations and TPM Coordinator

●Lead, drive and achieve cost saving initiatives, projects and processes throughout the manufacturing system by the base of value analysis and procurement & operational excellence.

●Reduce the consumption of resources and generation of waste by capturing existing data through energy monitoring system and take countermeasure against the excess consumption of power, air, consumables (diesel)

●Improve overall plant effectiveness (OPE) 75% by maintaining minimum inventory of parts < 6 days, thereby avoiding flaw less process flow from raw material (RM) to finished goods (FG)

●Deploy Eco-friendly, user friendly processes in shop floor, office and periphery to ensure workplace safety and to enhance total employee involvement.

●Govern the manufacturing process towards excellence by implementing good manufacturing practices like elimination of hammering, usage of open air, deburring of parts etc.

●Promote kaizen culture throughout the factory by conducting ICKC year on year for all working group also reward them on each category of Restorative, renovative, innovative and break through projects.

●Implement and drive companywide visual management system to enhance effective communication and reduce human errors.

●Form Cross function team (CFT) from top management to demonstrate ownership and results in manager model machines.

●Select Manager Model machines and test beds based on the previous history of PQCDSM, i.e. more no of breakdowns, producing frequent rejections, Cost of the operation, cycle time, hard to access and unsafe condition .

●Drive managers for initial cleaning daily in the select machines during Jishu Hozen time (JH) and educate operator to maintain the same after cleaning.

●Conducted Kick off since achieved the desired results in MMM and on the same day the rest of the machines handed over to operators to practice the same as like manager model machine.

●Create owner ship culture down the level by education and training, thereby demonstrate "I operate I maintain".

●Make the operators to identify abnormalities by tagging and support them to resolve within the time frame. White tag for solving on own and red tag for solving with the guidance of experts like maintenance and tool room.

●Frame policies and targets (KPI) for the plant, based on the KPI's top management will review monthly with TPM facilitators and pillar chairman.

●Present the progress of the drive and results achieved in plant during TPM senior counsellor CII visits in the presence of plant head, pillar chairman and functional heads.

●Drive pillar chairman to nominate circle leaders, and they will cascade the effect to circle members.

●Facilitate TPM counsellors and visitors by showing the results in shop floor, in the presence of them motivate circle leaders for best results.

●Drive the pillar chairman, circle leaders and members to achieve ZERO Breakdown, ZERO Accident and ZERO defect in machining cells, Engine assembly and test beds. Also facilitate education and training program for new comers through E&T pillar.

●Participate in CII kaizen competition and conferences to motivate circle leaders and thereby showcase the results achieved to other practicing companies, there by earn the goodwill to the organization.

●Achieved JH step 3 level in all machines by eliminating abnormalities & adhering daily to clean, lub, inspect,tighten & adjust schedule - CLITA through Autonomous maintenance .

●Facilitate elimination of source of contamination (SOC) & hard to access (HTA) in work place in-order to motivate circle members.

●Achieved Mean time between failures (MTBF) > 22 days from 17 days and Mean time taken to repair (MTTR) < 1.1 hr from 1.6 hr throughout machine shop through planned maintenance.

●Achieved OEE > 85% in machine shop and OLE > 95% in engine assembly by capturing major losses and reducing the same by taking counter measure in the form of kaizen through Kobetsu kaizen.

●Reduced rejection < 2000 PPM by deriving 4M condition, QM matrix, PM analysis and FMEA through Quality maintenance pillar & reached defect occurrences in single digit.

●Achieve Zero accident and near miss in single digit through safety, health and environmental pillar.

●Reduced material shortage, document time and losses due to logistics by office TPM.

●Create MP sheets based on the previous occurrences in the machines and equipments and imparts the improvement during new procurement of machines through development management.

●Derive Road map, master plan for the plant through each pillar and monitor month on month, show progress in monetary benefit with the concurrence of finance and plant head.

●Prepare activity report of plant, results achieved, company outline and for 8 pillars, get the concurrence from JIPM before final assessment for TPM Excellence.

April’11 - March’14: Greaves Cotton Limited, Ranipet. Tamilnadu. as Assistant Manager (Manufacturing) – Operations

Key Result Areas:

●Worked in Engine and Farm Vehicle Assembly & Testing Department as an Assistant Manager & lead a team of 240 members with age group of 20-55 and having rich experience in Union settlements negotiations and handling issues.

●Managed team functions like:

oControlling absenteeism & doing proactive leave planning as per absenteeism coverage provided

oResolving IR issues & manpower issues by doing counseling with team members

●Administered a Engine Assembly, Engine testing, Farm vehicle assembly & Testing, PDI; worked on:

oSingle cylinder Diesel engines from 2.5 HP to 18 HP (Including Petrol/Kerosene). Fed materials to assembly as per shift plan & planned changeover activities as per assembly requirements (supporting flex 5 assembly lines)

oAllotting the work for workmen as per their skills & qualification on day-to-day basis.

oMeeting Production, Quality targets and reporting day to day production status to Manufacturing Head (AGM).

oProcess in all operations utilizing of machine and man by effective planning.

oEstablishes production standards of efficiency, minimum wastage and maximum utilization of resources.

oPreparing of Assembly shop Daily, Monthly production report, report of rework & rejection analysis.

oEnsure usage of safe work practice & safety equipment inspection and analysis of assembly rejection & discussion to taking preventive action. Knowledge of measuring instruments, control plan, assembly processes.

oImplementation of 5s, TPM, POKAYOKE, KAIZEN Department level daily work management-PQCDSM targets.

oMaintain rejection at in House 270 PPM in Engine Assembly, 400 PPM in Engine Testing, 50 PPM in PDI of monthly by standardizing 4M Condition.

oMarching Towards Zero PPM at Customer End PDI through CFT, GEMBA and Implementing POKA YOKE by QA Matrix, 4M Condition Analysis in All Production Areas.

oEnsure reduction of rework. by8D& CAPA for Customer Complaints with in time line.

oEngaged with product improvement cell for Engine Lubricant Oil Consumption, Performance issues, Confirmation of product sample preparation

oGood understanding on EMS system. Involved in Year on Year 26% productivity improvement projects.

March’09 - April’11: Greaves Cotton Limited, Ranipet. Tamilnadu. as Senior Production Associate

oHandling Engine Testing, PDI section (20 Test beds & 3 PDI Conveyors).

oMeeting Monthly Allocation by Adhering Condition monitoring of equipment’s.

oEnsure Model wise Material planning and align to Production

oGiving Updations to dispatch for Customer Invoice planning. Coordinate with other sections for input material for core assembly section.

oInvolved in Year on Year 10% productivity improvement projects.

oReducing Tool Cost, Consumable Cost by eliminating SOC & HTA (ECRSAP method) in Shop Floor.

oReducing Rework & Rejection cost through Kaizens& Implementing low-cost automations in shop floor.

oCoordinate with Logistics function for planned finished goods inventory maintenance and align to dispatch plan.

o Developing Process and Compliance adherence for Assembly, Testing, PDI for HSE, World class Quality.

oReducing Unsafe Act & Un safe condition, Incidental, Near miss Accidents through SMAT Audit.

oImprove ergonomics through Kaizens (Fatigue reduction Kaizens)

oEnsure adherence to TPM process.

oManage manpower for all three shifts close to 180 persons. (120 – Union Cadre, 60 – DET’s)

oMotivating Operators and Diploma engineer Trainees through TPM, Education & Training (OJT, OPL).

Dec’04 - Mar’09: Greaves Cotton Limited, Ranipet. Tamilnadu. as Diploma Engineer Trainee

Key Result Areas:

●Worked in Crank case, Cylinder Head, Crank shaft, Cam Shaft, Connecting Rod, Cylinder Barell as a Trainee Engineer & operated all machines in the cell like:

●VMC (AMS), HMC (BFW), Gear hobbing process (HMT), Gear Shaving (Russian), Hardening (Inductotherm, Inducto heat), Tempering, annealing, lapping, Grinding (HMT, TOYODA), Honing (Nagel)

●Led Continuous Improvement Process (CIP) to improve productivity and quality; facilitated on-tooling, process characteristics and reduced product cost; contributed in achieving product PPM level as per as target

●Led the team & ensured achievement of daily and monthly production schedule with zero defect at customer line.

Apr’04 - Dec’04: Cafoma Auto parts Limited, Ranipet. Tamilnadu. as Maintenance labor

●Had training for Maintenance activities for SPM like RM62, RM64, VIKRAM Semi-automatic Lathe, NH24) and PM activities

EDUCATION DETAILS

BE - Mechanical from Aaarupadai Veedu Institute of Technology, Vinayaga Missions University, Chennai, in 2014; secured 67.80%

Diploma in Engineering (Mechanical) from Dr. MGR Polytechnic College, Arni, Tamilnadu in 2004; secured 70%

Trainings & Certifications:

●CNC Programming and Operations by VIT

●IMS (Integrated Manufacturing System (EMS: 18001 & OSHAS) Internal Auditor certified by TUV Nord.

●TS16949 Internal Auditor certified by TUV Nord.

●Light engineering goods packaging certified by IIP Chennai and MSME (Govt of India)

SOFTWARE SKILLS

●CNC Programming

●SAP MM

●Auto CAD

●MS Office

PERSONAL DETAILS

Date of Birth : 15th June 1984

Present Address : No: 781, Kala Rice mill street, Kamaraj Nagar, SIPCOT, Ranipet, Tamilnadu – 632403.

Permanent Address : No: 781, Kala Rice mill street, Kamaraj Nagar, SIPCOT, Ranipet, Tamilnadu - 632403

Languages Known : Tamil, English, Hindi, Telugu

DATE: PLACE: SIGNATURE:

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