Ramesh.R

Mobile No: +91-800*******(India)

Location: Bangalore, India.

E-Mail: adcq7m@r.postjobfree.com

LinkedIn profile:https://www.linkedin.com/in/rameshramankutty/ An Overview:

Operational excellence specialist with 9+ years of cross-industry operations experience in Auto ancillary sector, Electrical sector and structural steel sector.

Certified lean six sigma black belt Possess in-depth knowledge of lean manufacturing and six sigma methodologies along with additional continuous improvement practices.

Quality focussed visionary offering record of spearheading Lean transformations, improving organizational performances, maximizing productivity, eliminating waste, controlling costs, and driving organization excellence. Competent on:

Career Summary:

Company Products Delivered

Tenure

Job Title Key Achievements

Jeddah,Saudi Arabia

●Structural

steel

2.1yrs

Sep'17-Nov'19

Specialist-

operational

excellence

●Design and implementation of painting line for

light weight structural steel with a savings of

$500k million per year ● Implemented direct

dispatch from the painting line with a savings of

$105k million per year

Bangalore,India

●Cooling unit

●PDU

0.9yrs

Dec'16-Sep'17

Sr. industrial

engineer

● Line balancing and Relayout of cooling unit

assembly ● E-Kanban Design and implementation

● Integrated Nutrunners in the concept of IoT.

Hyderabad,India

●ACB

●MCCB

●Contactors

3.1yrs

Oct'13-Dec'16

Sr. Methods

engineer

● ACB production capacity increase from 9/Hr to

40/Hr ● MCCB production capacity increase

from122/Hr to 360/Hr ● Contactors production

capacity increase from 150/Hr to 200/Hr

● Visited china to implement MCCB rotary handle

production in Hyderabad factory

● Presented Lean project in all India level CI day competition from Hyderabad factory

Chennai,India

●Wire

Harness for

cars and

trucks

3.3yrs

July'10-Oct'13

Sr.

Manufacturing

engineer

●Established Standard me for all wire harness

assembly process ● Established Line balancing

and re-layout for all existing assembly process

● Established new assembly line setup for ford

EcoSport in a new factory ● Developed Domesc

vendor for jigs and fixtures.

Lean Principles Poka-yoke & Jidoka’s Capex Budget planning

Six Sigma projects-DMAIC TPM implementation Vendor development

Project management-PMP TQM implementation Automation solutions

Mfg. Change management Digitization & IoT Functionality Test benches

Efficiency & Productivity (OEE) Ergonomics & OSHA Mentoring & Training

Kaizen-Continuous improvement Time & Method study Schneider production system

Value stream mapping (VSM) New process development Structural steel painting process

Kanban system Capacity planning & Mgmt. Special purpose machine conceptualisation

Responsibilities:

Since Sep’17 AIC steel, Arabian International company, Jeddah, Saudi Arabia

● Developing and implementing a sustainable strategy for operational excellence ● Develop and establish AIC production system ● lean Manufacturing implementation and continuous improvement projects ● Develop manufacturing methods, labour utilization standards, and cost analysis ● Plan and implement productivity improvement initiatives ● Improve operations performance by applying Lean principles & six sigma DMAIC tools● Implementation of manufacturing techniques (lean, 6 Sigma, 5S, value stream mapping; pull systems, SMED, TPM, and Kaizen etc. to improve workflow; reduce cycle time, and costs ● Recommend modifications to existing quality or production standards by referring to best applicable practices Oct’13-Sep’17 APC, Bangalore & Schneider electric India private limited, Hyderabad.

● Capacity management ● Line architecture design methodology ● Debottleneck the bottleneck and time traps in the process ● Line balancing ● Design time estimation and design time reduction in process ● TIMWOOD approach for identify waste in process ● DMAIC approach for lean projects ● KANBAN calculation and implementation in Gemba and warehouse ● Water- spider concept implementation ● Process FMEA discussion and preparation ● Poka-yoke and jidoka’s implementation in process

● BOM updations (maintained in SAP) ● Design ECN (engineering change notes) implementations ● JBS (job breakdown sheet) and OWS (operator work standards) preparation and updations ● Machine design, qualifications and improvements ● Prioritization and identification of major contributors for NPT (non-productive time) ● Direct labour productivity estimation and improvements ● Achieve Industrial efficiency and sustain ● Understanding Schneider production system principles and implementing it in process ● Time study through MTM methodology and live process measurement with stopwatch ● Encourage and collect ideas from employees and implement it for process improvements ● Ergonomy analysis and safety improvements through overall risk assessment in production lines. Jul ‘10-Oct ‘13 Yazaki Wiring Technology India Pvt. Ltd. Chennai

● Coordinating with different functions of new product development ● Design and development of assembly processes ● Creation of ECR documents ● Implementation of design changes ● Updating the schematics based on the design changes ● Use of ERP software MFG Pro for effective material planning ● Preparation of PFMEA for new process ● Establishing time standards for new products/ process standards ● Procurement globally and locally of equipment’s required for processes ● Layout making for new process/Plant ● Statistical validation of the installed processes to meet the product requirements ● Functional expertise in the field of new product development and Development of components ● Preparation of Wiring Harness drawings using AutoCAD with respect to ECRs ● Analysing the customer drawing and developing prototype ● Tracking the daily production and help production to achieve the required productivity and efficiency ● Kaizen implementations which result in robust work ergonomics and manufacturing cost reductions

Trainings & Skills:

Key Trainings Software skills Language skills

Lean six sigma Auto CAD 2018 English

PMP 35 hours course PMBOK 6th edition MS Excel/PowerPoint Hindi

Schneider production system (SPS) MS Project Tamil

MTM time study SAP SRM (Purchase Request tool) Malayalam

7 Habits of highly effective people IFS ERP Software Telugu

7 QC tools QAD MFG Pro ERP Software

APQP

Highest Education:

Bachelor of Engineering (B.E) in Mechanical Engineering from Asan memorial College of Engineering- Anna University, Chennai with 66% in 2010

Personal Details:

Nationality: Indian

Passport Available: Yes

Year of Birth: 1989

Marital status: Married

Dependents: Spouse & Daughter

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