Resume

Sign in

Management Manager

Location:
Hosur, Tamil Nadu, India
Posted:
December 23, 2019

Contact this candidate

Resume:

KUPPA RAJAN GOPINATH

Mobile: +91-944******* / +91-967*******

E-Mail: ada4qu@r.postjobfree.com

Professional Preface

A Dynamic Professional With Overall Experience Of 29+ Years, Out Of Which 10+ Years In Third Party Auditing Comprises Of ISO 9001, 14001,18001, 45001, 50001, 29990 Standards, 7 Years In QEOHS System Implementer & Performer, 2 Years in Teaching, 12 Years In Industrial Engineering Related With Resources Optimization Possessing Strong Communication, Team Management, Relationship Management, Coordination And Analytical Skills. Qualification

M.E. (Industrial Engineering) Anna University, Chennai 1993 B.E. (Mechanical Engineering) Bharathiar University, Coimbatore 1988 DMM Maintenance Management Annamalai University 1990 Skill Set And Technical Competence

ISO STANDARDS

ISO 9001 :2015 ISO 14001:2015 BS OHSAS 18001:2007 SEDEX [SMETA] Audits. ISO 45001:2018 ISO 5001:2011 ISO 29990:2010

EHS

EHS Planning EHS Awareness / Training EHS Documentation HIRA & Risk Assessment EHS Compliance Incident Investigations / CAPA Contractor Safety Change Management EHS Performance EHS Auditing PPEs Compliance / Safety Culture INDUSTRIAL ENGINEERING

Work Measurement Line Balancing Inventory Control Productivity Improvement Operation Research Facilities Planning Capacity Utilization Standard Data Manual Systems Engg Quality Engg Logistics and SCM Safety Engg Ergonomics & Human factor Engg Value Engg Project Management ISO Auditing [Third Party Audits]

Distinction of verify the system conformance to standard requirements of ISO 9001:2015, ISO 14001:2015 BS OHSAS 18001:2007 / ISO 45001:2018 / ISO 50001:2011 and Compliance & Compliance mechanism, System Performance for the QEOHS and Energy Management Systems Implemented and Non Formal Education Sector in line with ISO 29990 standards. ISO System Implementation

Distinction of establishing, implementing, maintaining, continually improving and sustenance of ISO 9001 Quality Management Systems, ISO 14001 Environmental Management Systems & OHSAS 18001 Occupational Health and Safety Management Systems.

Monitoring adherence to quality, environment and OH&S management systems and complying with standard requirements; establishing 5S culture through structured training and internal audit verification mechanism.

Industrial Engineering

Expertise in handling the complete plant activities entailing effective and efficient resource utilization, productivity improvement, quality management & man management.

Hands on experience in:

Coordinating plant activities for the set up standards with accountability for strategic utilization & deployment of available resources to achieve organizational objectives.

Implementing focused improvement programs to address bottlenecks in manufacturing systems for optimum utilization.

Identifying opportunities for improvement using various techniques & tools.

Recommending appropriate methods to enhance operational efficiencies of the systems.

Improving profitability, productivity and cost reduction programs.

An enterprising leader with proven abilities in leading teams towards the achievement of organizational goals and industry best practices.

Excellent relationship management, analytical skills with deftness in swiftly ramping up projects / plant activities.

Career Highlights

Apr’18 to tilldate Sr IMS Lead Auditor : Quality, Environment, Health & Safety and Energy Management Systems

Tuv India Private Limited [Tuv Nord Group], Chennai Jun ‘15 to Feb ‘18 Lead Auditor : Quality, Environment, Health & Safety Management Systems Tuv-Sud South Asia Private Limited, Chennai

Feb ‘09 to Apr ‘15 Lead Auditor : Quality, Environment, Health & Safety, Energy and RMC Compliance Auditor – Wage, Labour, Environment and Health Standards Bureau Veritas Certification India Private Limited, Chennai Key Responsibilities:

Strongly possess the ability & leadership, inter personal, communication, organizational and management skills to lead, motivate and manage the audit team & performance.

Prepare. Plan, Organize, Implement the audit plan as per contractual agreement / ISO 17021 requirements and CB Related Internal Management System Requirements.

Able to plan, organize and implement the audit plan.

Ensure timely execution of audits, timely submission of audit reports.

Ability to interact with all levels of management, consultants and clients. Extensive knowledge and competent of the relevant standards.

Ensure compliance with respective global documentations and local procedures in accordance with accreditation bodies requirements while conducting audits.

Have a rich and sound exposure of auditing and verifying the conformance to standard requirements and compliance level & compliance mechanism, system performance for the Quality, Environmental. Occupational Health & Safety and Energy Management Systems. Major Accomplishments:

Audited different type of industries including engineering, cement, construction, fabrication, automobile, transport, electrical, electronics, information systems, instrumentation & control, plastics, rubber, pharmaceuticals, chemical, hotel, hospital, textile, rayon, leather, glass, asbestos related, printing press, garments, fibres, engg & other services viz leads to 1782 man days approx. Jan’08 to Jan’09 Freelance Consultant

Key Responsibilities:

Demonstrate excellence in completing assignments undertaken. Major Accomplishments:

ISO 9001:2008 Quality Management Systems – M/s. Design Desk, Chennai

Developed/ Implemented Quality Management Systems in a small automotive design company at Chennai. Work measurement at automotive company manufacturing clutches in Hosur. ISO 14001:2004 and OHSAS 18001:2007 Integrated Management Systems – M/s. ICF, Chennai and M/s. Prism Cement, Satna, MP

For a cement manufacturing and railway coach production units–

Identify hazards & risks related to its all activities and situations that could give rise to the potential of injury, illness, death.

Assess and control of risks to determine the priorities of the level of risks of injury or illness associated with each identified hazards for the purpose of control.

Risk Control Action Plans are established for all significant hazards and risks and compliance requirements.

Identify all legal and other requirements that are applicable to the EHS. Haz wastes disposal including e- wastes

Identified operational control procedures for those operations and activities that are associated with the significant hazards/risks where their absence could lead to deviations from the organizations policy and objectives.

Identification of training need and to organize required training for staff on EHS.

Organizing periodical quality, environment and occupational health and safety meetings.

Coordinating for conducting plant safety inspections and safety audits.

Effective implementation of integrated management systems comprises of environmental, occupational health & safety towards continual improvement and sustainable development. Jan’01 – Dec’07

Manager – Industrial Engineering & Management Representative (QEHS) – ISO Systems Madras Cements Ltd., Alathiyur Works, Ariyalur Dt.,Tamilnadu Management Representative – QEHS

Identifying the processes needed for Quality Management System and to determine the sequence and interaction of the processes identified.

Implement and put into practices of type and extent of control for the outsourced processes.

Planning and System documentation.

Managing of QEHS documents and contract administration as well as associated retention rules.

Develop the overall strategy of continuous improvement for company’s Quality, Environmental, Occupational Health and Safety Initiatives.

Identifying and updating environmental aspects & impacts on the environment of various processes and activities and hazards & risks and evaluate the accident producing potential of systems, processes and activities.

Effective implementation of QEHS programs, policies, procedures, training, work practices and controls.

Responsible for identifying applicable EHS regulations and risks while interacting with Operations, Planning, Legal, Engineering, to implement acceptable systems in order to ensure compliance and conformance to EHS Policies and Management System.

Participation in budget preparation and tracking, establishing and monitoring progress toward department goals.

Managing environmental processes in operations to assure proper waste management.

Ensuring compliance with all statutory requirements concerning EHS.

Ensure no disruptions on account of Pollution control.

Audit (internal & external) execution follow up closure of NCRs.

Green belt development for plant & mines.

Identification of training need and to organize required training for staff on EHS.

Organizing periodical quality, environment and occupational health and safety meetings.

Conducting plant safety inspections and safety audits.

Development of safety manual, work instructions etc. and assisting departments in implementation, compliance.

Imparting safety trainings to all categories of permanent or temporary employees

Investigation & Analysis of accidents and near misses and assisting departments to improve their safety standards and performance.

Promote achievement of the company EHS aims and targets; drive compliance to company EHS policies, principles, procedures and practices.

Direct, supervise and evaluate work activities of medical, nursing, technical, clerical, service, maintenance, and other personnel.

Review and analyze facilities, activities and data to aid planning and risk management and to improve service utilization.

Inspect facilities and recommend building or equipment modifications to ensure emergency readiness and compliance to access, safety, and sanitation regulations.

Consult with medical, business, and community groups to discuss service problems, respond to community needs, enhance public relations, coordinate activities and plans, and promote health programs.

Monitoring the performance evaluation on quality, environment & health and safety systems.

Identify and evaluate opportunities for improvement. Prioritize improvement opportunities based on impact, needs and resource.

Follow up on the implementation.

Conduct risk assessment of the proposed change to determine its effect on reducing QEHS risks and hazards. Implement required and validated changes through change management protocols.

Deliver training program on a defined frequency to all applicable levels and functions of the organization. Review effectiveness of the training plan and adjust accordingly

Determining the review of QMS, EMS & OHSMS to ensure continuing suitability, adequacy and effectiveness.

Effective implementation of integrated management systems comprises of quality, environmental, occupational health & safety towards continual improvement and sustainable development. Manager – Industrial Engineering

Work Measurement and Productivity Improvement

Manpower Optimization

Inventory Control

Feasibility and Plant Layout Study

Capacity Utilization

Optimization Techniques

Application of Operation Research Methodologies

Standardization of Forms & Formats /

Design, development and implementation of Cost Control & Cost Reduction Programs

Application of 7 QC Tools

Resource conservation measures

Major Accomplishments :

Improvements in Productivity and Profitability:

Achieved 22% inventory reduction from existing Rs.538lacs to Rs.441lacs and considerable cost savings towards inventory carrying cost to the tune of Rs.19.4lacs.

Developed and Implemented Transportation model for cement dispatches from factory to various demand destinations by satisfying their requirements within plant capacity available.

Established, Implemented and Ensuring continual improvement of Quality Management Systems, Environmental Management Systems & Occupational Health and Safety Management Systems.

Implemented management programmes with the measurable targets for achieving Quality, Environmental and OH&S objectives.

Developed & implemented the following:

Simplified purchase procedures to minimize internal lead time and to control inventories.

Methods & systems to minimize inter mines delays & improved limestone transport from 3400tpd to 3530tpd.

Methods and systems for Crusher productivity improvement from 650tph to 689tph.

Methods for improvement in capacity utilization of roto packer from existing 150tph to 162tph.

[under ideal conditions, it is 180 tph]

Procedure simplification of factory order processing through office and method study

Methods improvement and reduce paper bags damage from 1.08% to 0.50% and achieved cost savings to the tune of Rs.0.54lacs/annum.

Appropriate methods to stock maximum raw material inventory by effective cubic utilization of space in additive storage shed.

Simplified methods to improve raw material unloading and thereby minimize raw material lorries waiting time.

Redesign factory layout for cement loaded lorries movement to eliminate traffic congestion inside factory premises.

Improvements in Water Conservation Measures :

Reducing Boiler Water Blow Down

Fixing Of Water Flow Meters At The Identified Points.

Implemented Controls On Water Tapping

Reducing Frequency Of Venting /Triping To Avoid Condensate Loss Improvements in Various Energy Conservation Projects :

Achieved rotor packer output to 1650 bags / hr against the target of 1800 bags / hr from 1500 bags/hr through various optimisation techniques there by reduced energy consumption.

Implement The Usage Of Other Alternate Fuels Like Organic Wastes And Pet Coke For Kiln Firing Towards Coal Conservation.

Standardised On The Variety Of Spares And General Consumables Without Compromising On QHSE Issues.

Improvements in Various Water Conservation Measures

Reducing Boiler Water Blow Down

Fixing Of Water Flow Meters At The Identified Points.

Implemented Controls On Water Tapping

Reducing Frequency Of Venting /Tripping To Avoid Condensate Loss Improvements - Environment, Health and Safety

Optimise Energy Consumption In Material Handling of Limestone By Implementing Appropriate Methods To Minimize Inter Mines Delay, Improve Limestone Transport

Achieved Considerable Energy Savings For Surface Miner By Optimising No Of Hauling Equipments Thru Cycle Time Reduction

Minimise Dust Emissions By Replacing Polyster Bag Filters With Copolymer Bag Filters.

Implement Dust Suppression Systems To Reduce & Control Dust Emissions While Coal And Raw Material Additives Unloading From Truck Tipplers.

Implement Road Sweeping Machine To Reduce Fugitive Dust Emissions From Floor And Road Cleaning

Implement Methods For The Prevention Of Oil Entering In To Land And Drainage.

Reduce And Control Dust Emissions By Diagnosing And Correct Causes Of Poor Quality Of Pager Bags Burstage.

Achieved control of bag breakages is 0.129% [global standard – 0.025%]. Cost savings achieved due to the change in 3 ply to 2 ply.

Improvements in Occupational Health & Safety Related Projects :

Provide appropriate speed breakers at relevant places to prevent accident from empty and loaded lorries while parking or on the roads.

Minimise dust emissions by replacing polyster bag filters with copolymer bag filters.

Implement dust suppression systems to reduce & control dust emissions while coal and raw material additives unloading from truck tipplers.

Implement road sweeping machine to reduce fugitive dust emissions from floor and road cleaning

Implement methods for the prevention of oil entering in to land and drainage.

Reduce and control dust emisisions by diagnosing and correct causes of poor quality of pager bags burstage.

Develop safe work practices for common construction activities to prevent and control fall from height. Example : Roof truss installation [housing]

Develop the means and promoted the use of mechanical lifting aids during manual / material handling.

Develop and promote technological advancement in evaluating safety rating of power tools to prevent and control repetitive strain injuries. Examples : Angle grinders, Vibration reduction and saw guards.

Develop safe work practices and use of ladders to prevent and control fall from height in different scenarios.

Improvements in Civil Projects :

Involved in the coordination of optimum resource utilization during the construction of civil buildings / structures right from the soil exploration, foundation, design mix, applicable statutory approvals pertained to the constructions, testing of water / steel, cement, aggregates, for construction as per IS standards.

Achieved cement wastage 0.6% against the target of 2%.

Achieved reinforced and structural steel wastage as 2.4% against the target of 3%.

RMC wastage is totally eliminated.

Project Study : Assessment of Energy Conservation And Reduction of Carbon Emissions In Cement Plant

A project study has been conducted on assessment of energy conservation measures, carbon emissions and mitigation of carbon emissions from the cement plant. The principal objective of taken up this project work is to conduct process wise energy and exergy analysis, to identify the potential areas of energy conservation opportunities, analysis of data on fuel usage, electricity consumption and amount of clinker and cement production to estimate CO2 emissions, to perform decomposition analysis of the change in CO2 emissions, to develop a basic dynamic model for forecasting CO2 emissions with the available information, and to develop the modified model to forecast the cement production and CO2 emissions in under various scenarios. The study concludes, by adopting technology improvement & waste heat recovery system for improving exergy efficiency in rawmill, cement mill, improve thermal performance of the kiln thereby reducing energy losses, implementation of renewable energy a replacement for electrical energy and green belt development, energy conservation and carbon emissions could be considerably achieved. Jan’00 – Dec’00

Freelance Consultant

Key Responsibilities:

Demonstrate excellence in completing work measurement and productivity improvement assignments Major Accomplishments:

Reduced Rejection Level from 1.1% to 0.6% for M/s. Eveready Industries India Ltd., Chennai.

Ensured Effective Cubic Utilization Of Floor Space by re-desigining layout for M/s. Easun Group of Companies, Chennai.

Successfully increased production by 20% for M/s. Royal Enfield Motors, Chennai through work measurement, assembly line balancing, optimizing manpower.

Minimize sales and distribution costs and increase productivity for M/s. Amrutanjan Ltd., Chennai through Method study.

Apr’96 – Nov’99

Senior Industrial Engineer

Shasun Chemicals and Drugs Limited, Cuddalore.

Key Responsibilities:

Develop and Implement Inventory Control Systems for Engg. Materials.

Man Management.

Develop and implement optimization techniques, water & energy conservation measures and cost reduction programs.

Major Accomplishments:

Implemented Suggestion Scheme & achieved cost savings to the tune of Rs. 2.16 lacs.

Developed & Formulated Production Incentive linked with capacity utilization.

Conducted manpower optimization in production, stores & packing plant departments resulted in considerable cost savings up to Rs.4.28 lacs /annum.

Achieved considerable cost savings by conducting cost reduction exercises on water consumption, variety reduction & standardization of forms & formats.

Improvement in water conservation measures

Conducted Feasibility Study On Water Conservation Measures And Implemented

By Installing And Commissioning Of Water Jet Ejector For Generating Vacuum

Achieved Results Are Optimum Water Consumption

Reduced Effluent Discharge And

Reduced Power Consumption For Effluent Treatment. Improvement in power conservation measures

Achieved In Reduction Of Considerable Power Savings By Downsizing With Appropriate Motor Capacity For Ranitidine Plant Centrifuges

Develop And Implement Vendor For Vendor Evaluation System For Incoming Quality Materials / Spares

/ Packing Matls.

Reduce Resource Consumption By Appropriate Form Design And Standardised Various Forms And Formats

Developed And Implemented Suggestion Scheme For Promoting Quality Culture, Energy And Resources Consumption Measures, Waste Control, Cost Control, Safe Work Practices, Good House Keeping And Better Environment

Project on waste management treatment and control measures

Minimize the quantities of hazardous materials used and select materials whose wastes can be controlled, recovered and recycled, whenever possible.

Develop and install systems for recycling raw materials (e.g., solvents), intermediates, wastes and utility materials (e.g., cooling water, heat transfer liquids, lubricants, steam condensate).

Examine reactants, solvents and catalysts to optimize the efficiency of chemical reactions.

Modify the design and features of processing equipment to minimize pollution and wastes.

Improve processes to maximize product yields and desired properties, eliminating additional processing (e.g., re-crystallization, drying and milling).

Consider using multi-purpose equipment (e.g., reactors, filters and dryers) to reduce pollution and wastes during transfers, cleaning and additional process steps.

Use appropriate instruments, automated control systems and computer programs to maximize the efficiency of processes and reduce pollution and wastes

Implement appropriate methods for waste management control and waste water tgreatment in canteen Operations. Wastewater treatment facility operators may be exposed to physical, chemical, and biological hazards viz includes the potential for trips and falls into tanks, confined space entries for maintenance operations, and inhalation of VOCs, bioaerosols, and methane, contact with pathogens and vectors, and use of potentially hazardous chemicals, including chlorine, sodium and calcium hypochlorite, and ammonia.

Project on productivity improvement

Conduct Detailed Production Study And Arrive Optimise Man Power For Production Department Involved In Ranitidine, NMSM, Ibuprofen By Stream Lining And Considering The Criticality Of Activities & Various Stages During Product Realisation.

Jan’93 – Mar’96 Industrial Engineer

Tata International Ltd., Dewas, Madhya Pradesh

Key Responsibilities:

Conduct method study, direct and indirect work measurement.

Conduct productivity improvement studies.

Standardization of Forms & Formats /

Implementation of Cost Control & Cost Reduction Programs

Application of 7 QC Tools

Feasibility and Plant Layout Study

Optimisation of resources

Major Accomplishments:

Developed and Implemented Standard Data Manual for leather garments & leather articles providing a base for planning, time requirement and cost estimating.

Increased production output by 11% for short cycle and machinery loading operations.

Successfully increased labour productivity by 13% by revising production norms through time & motion study, pre-determined time standards (PDTS) and work factor (WOFAC) methods.

Optimize clerical Staff.

Project on water conservation measures

Conducted Feasibility Study On Water Conservation Measures And Implemented By Fixing Of Water Flow Meters At The Identified Points and Implemented Controls On Water Tapping. Achieved Results Are Optimum Water Consumption.

Project on power conservation measures

Conducted Feasibility Study On Energy Conservation Measures And Implemented By Replacement Of Oversized / Undersized Motors By Right Size Motors To Achieve Electrical Energy Consumption In The Aletti Shaving M/C, Monalissa, Lighting Buffing, Roto Spray, Wooden Dying Drums And Hand Spray Booth.

Project on resource conservation measures

Reduce Resource Consumption Like Power Consumption, Chemicals Consumption, Water Consumption. Thru optimisation techniques and optimising the key process parameters.

Minimise Coal Consumption With The Installation And Commissioning Of Flash Steam Recovery System In The Boiler.

Project on productivity improvement measures

Reduce Time, Effort And Manpower Thru Implementing Mechanisation / Low Cost Automation In The Plant Layout

Increase Machine Productivity Through Condition Based Monitoring

Conduct job hazard analysis to set performance standards, assist in standardization of the operations based on acceptable safe practices and PPE.

PREVIOUS EMPLOYMENT

Aug’90 – Aug’91 Trainee Govt. Automobile Workshop, Madurai Nov’88 – Aug’90 Lecturer Seethai Ammal Polytechnic, Sivagangai Dt. Tamilnadu Training Courses

Attended the following courses for enhancing competence and skill :

Lead Auditor Transition Training Course For ISO 50001:2018 EnMS From Tuv India, Jan 2019.

Lead Auditor Transition Training Course For ISO 45001:2018 OHSMS From Tuv India, May 2018.

Lead Auditor Trained On Non Formal Education Sector In Line With ISO 29990:2010, May 2017.

Lead Auditor Conversion Course For ISO 9001:2015 QMS From Tuv-Sud, Feb 2016.

Lead Auditor Conversion Course For ISO 14001:2015 EMS From BSI, Dec 2015.

Occupational Safety & Health Training Course On Welding, Cutting And Brazing Safety By OSHAcademy, Dec 2017

Occupational Safety & Health Training Course On Nail Gun Safety By OSHAcademy, Dec 2016.

Occupational Safety & Health Training Course On Stairway And Ladder Safety By OSHAcademy, Dec 2016.

Occupational Safety & Health Training Course On Ergonomics Program Management By OSHAcademy, Jun 2016.

Occupational Safety & Health Training Course On Confined Space Program By OSHAcademy, Dec 2015.

Occupational Safety & Health Training Course On Housekeeping Safety By OSHAcademy, Nov 2015.

Auditor Trained On Ready Mix Concrete [RMC] Capability Audits In Line With ISO 17065.

Lead Auditor Conversion Course For EnMS Lead Auditor From BVCI, Chennai.

Lead Auditor Conversion Course For OHSAS Lead Auditor From BVCI, Chennai.

Compliance Auditor Trained On SEDEX [SMETA] In Line With 4 Pillars.

Lead Auditor Conversion Course For ISO 9001:2008 QMS From BVCI, Apr 2009.

Lead Auditor Course On ISO 9001:2000 QMS And ISO 14001:2004 EMS At Management Quality & Consultancy Services, Chennai.

Training On Information & Security Management System At Quality Council Of India, New Delhi

Integrated Management Systems – Internal Auditors Training At Management Quality & Consultancy Services, Chennai

Occupational Health and Safety Management Systems at National Safety Council, Mumbai

Auditing of QMS at Institute of Standard Engineers, Chennai

Training course on Internal Auditing in QMS, EMS and OHSMS.

Value Engg. for Quality & Cost Management at National Institution for Quality & Reliability, Chennai. Professional Membership

Life Member - Madras Productivity Council, Chennai Life Member - National Institution for Quality and Reliability, Chennai Associate Member - National Council for Industrial Harmony, Chennai IT Skills

Proficiency with MS Word / Excel / PowerPoint / Project Manager / ABC Flow Charter / Visio in Windows Platform. Personal Details

Date of Birth : 11th March, 1966

Address : # 19, Mythri Nilaya, Second Floor, Indira Nagar, Bagalur Road, Hosur 635109 Address for

Communication : 12/50, Swamy Illam, 13th Cross, New Colony, Chromepet, Chennai 600 044 References : Available on request

Place : Hosur

Date : 30 / 08 / 2019



Contact this candidate