Plant Manager

K.ARUNACHALAM

Phone: +91-984**-***** Email: ************@*****.**.**

Seeking middle level assignments in Production Planning & Control/ Process Enhancement & Cost Control/ Quality Assurance with a reputed organization.

PROFESSIONAL PROFILE

A Competent professional with over 17+years of qualitative experience in Production Planning & Management, Material Management, Quality Management as well as Inventory Control in the Motor Manufacturing, Automobile& Electronics Manufacturing Sector.

Last i associated with Mando Automotive India Private Limited, Chennai as a Manager – Production.

Deftness in heading overall production operations with a view to ensure timely accomplishments of production targets within the time and cost parameters.

Served as a member of CFT and coordinating various activities like Prototype development and new supplier’s identification.

Proficient in carrying out assessment of the performance of the vendors based on various criterions such as Technical compatibility, process requirement, and vendor reputation in terms of integrity, openness & transparency.

Possess excellent communication and relationship management.

AREAS OF EXPOSURE/ EXPERTISE

Production

Supervising the production operations, allocation of resources and costing of the products after due approvals by the buyers of the samples.

Monitoring & controlling Critical Machine down Time via OEE improvement meetings.

Ensuring PPPD improvement by recommending new scheduling process ensuring increase in production level & significant reduction in man-hours, errors and waste.

Monitoring & controlling the scrap trend by SFT meetings

Making decision of norms of change of spares in M/Cs and maintaining the proper Housekeeping in Shop floor.

Preparing Feasibility Report and recommending design modifications based on internal and external client requirements.

Responding customer with 8D report and taking actions on complaints

Process Enhancement & Cost Control

Implementing process enhancement techniques for smooth flow of operations.

Executing cost saving and energy saving techniques/ measures and modifications to achieve substantial reduction in O&M expenditures and work within the budget.

Handling operations for improvement in existing products based on market trends.

Taking QAAP improvement activities and coordinating various activities like APQP, PPAP, Prototype development and new supplier’s identification.

Doing Product and process Audit, Analyzing daily internal rejections and initiating corrective and preventive actions for the internal rejection.

Vendor Development/Sourcing

Identifying and developing vendor source for achieving cost effective purchases of machines and tools and reduction in delivery time.

Assessment of the performance of vendors on various criterions such as percentage for rejections, quality improvement rate, timely delivery etc

Overseeing follow-up with vendors for deliveries and quality checks & ensuring timely payments.

Quality Assurance

Conducting random online quality inspections to ensure that product quality standards are adhered to at all stages of the manufacturing process.

Adopting, implementing & monitoring better techniques to improve quality & productivity

Responsible for the continual improvement of the quality system.

EXPERIENCE DETAILS

Sep’18 to Mar ‘19 Mando Automotive India Private Limited, Chennai as a Manager –Production.

Reporting to the Business Head.

Developing and implementing the manufacturing strategy for the company

Liaising effectively with global factories to ensure effective technology transfer

Working closely with the global leadership team to ensure alignment with the global manufacturing strategy

Preparing Department budget as per Business Plan.

Inventory turnover days reduced and maintain as per target through Material Planning.

Driving continuous improvement projects across the value chain, thereby promoting operational efficiency

Training and mentoring staff across levels

Managing the Autonomous Production Unit Managers and of the support function managers (HR, Quality, Finance, Logistics, Purchasing,- )

Ensure smooth inbound and outbound information flows

Ensure customer satisfaction

Drive plant Quality, Cost, Delivery and People (QCDP) performance and build and meet the plant budget

Drive product/process QCD improvement;

Optimize plant lay-out and equipment usage

Ensure manufacturing readiness and launches at plant level

Drive supplier performance improvement

Define a deployment plan for the HPS – Halla Production System and implement it

Drive plant improvement networks and involve everyone in continuous improvement processes

Ensure employees safety, respect for the environment and security of the plant

Fulfil legal responsibilities and interface with local authorities

Ensure staffing, induction, training and development of plant employees

Manage social climate and labour relations

Develop future experts and managers

Significant Highlights

Achieved 420 Nos ABS RHD Assembly in Single Shift.

Successfully New Line EBS implemented with Korean team support.

Nov’16 to Sep’17 KENWIN Private Limited, Chennai as a Manager –Production.

Plant setup & Layout optimization.

Machine installation & Commissioning activities.

Co-ordination with Spain team for new development activities.

Recruiting Staff and Operating Manpower for Operation

Product assembly, Site Measurement & installation training given to Technicians.

Monthly MIS Report preparation for Board meeting.

Site Measurement & Installation trainings given to all dealers.

Import and Local Material Planning

Production Planning & Management

Factory facility Management

Co-ordination for Dispatch Activities.

Operation Budget Preparation

Apr’15 to Jul’16 Varroc Engineering Private Limited, Chennai Deputy Manager –Operations. (Plant

Head)

Plant setup & Layout optimization.

Machine installation & Commissioning activities.

Co-ordination with our Plant HR & Corporate team for Liaison activities, Statutory Compliance for new Plant.

Staff & Operators Recruitment

Product & Process Training given to the team

Co-ordination with our Marketing, Project Management, R & D, Corporate Materials for New program activities.

Co-ordination with our customer for Try-out & PPAP activities.

Handling operations including Manufacturing, Quality, Stores, Logistics, Purchase, Statutory Compliances and other relevant functions

Ensure Customer satisfaction

Ensure employees safety, respect for the environment and security of the plant

Ensure staffing, induction, training and development of plant employees

Drive supplier performance improvement

Drive product/process QCD improvement;

Drive plant Quality, Cost, Delivery and People (QCDP) performance and build and meet the Plant target

Ensure smooth inbound and outbound information flows

MIS Report preparation.

Maintain 5S.

Significant Highlights

Two models (Classic 500CC & D71) PPAP completed successfully.

Zero Customer compliant from Day one.

Reached 500 Nos HB Assy / day in short span of one month Period.

Nov’07 ~ Oct’08 Varroc Engineering Pvt. Ltd Executive –Production

–Actively involved in supervising around 20 engineers and achieving the targeted production in & delivering the goods on time with quality as per customer specification.

–Co-coordinating with various departments like R&D for new projects, PED for Capacity Enhancement activities, Quality for reducing In-house PPM and M/C Setters & Maintenance team for OEE improvement.

Type & Product Manufacturing

–M/s Varroc Engineering Private limited is a leading manufacturer of Starter motors, wiper motors, FWM, Handle bar assy, Dash board assy, Switches, Head lamp, Tail lamp, Blinkers, Electronics clusters, CDI, Regulators, Rectifiers, AC generators etc. Varroc Group has 19 plants: 14 in Western India, 3 in Northern India and two in Europe with head quarters in Aurangabad.

Significant Highlights

–Successfully launched Varroc’s first Export Business within three months of joining.

–Instrumental in supplying products to various key clients like Bajaj Auto Limited, Royal Enfield Motors, BOS – German & China and Yamaha Motors India Limited

Comstar Automotive Technologies Private Limited, Chennai as a Deputy Manager –Production (Dec’17 to Aug’18).

Armature Assembly –Weekly Production Planning & scheduling.

Weekly MIS Review

Monthly Finance Review document Preparation.

Daily Plan Vs Actual review with Line Engineers

Daily Rejection review with Line TMT & Engineers.

Maintain & Improve -5S & 3C activities at shop floor

SGA, Suggestion & Kaizen - Implementation

Co-ordination with Planning & MP&L Team for Materials

Co-ordination with MSE & CBG Team for New Products

Co-ordination with Sales team for Aftermarket Products.

Maintain Inventory as per Plant Norms.

Significant Highlights

Achieved 8000 Nos armature Assembly in 2 Shift Basis.

Dock audit PPM reduced to 700 PPM.

Assistant Manager– Starter Final Assembly Nov’12 to Jan-15

Coordination with all sub assembly departments.

Daily Rejection Analysis in GENBA Meeting with CFT.

Prepare daily and weekly Plan.

Ensure Weekly schedule adherence.

MIS Report preparation.

Maintain 5S.

Coordinating SGA team in Final assembly.

Take corrective action through 8D for Customer & Internal Concerns.

Training given to New operators.

After Market-Production Planning & Execution.

Spares Planning & Packing

Union related issue Handling

Significant Highlights

Starters Production / day -7K Consistently

AEN 100%

Auto Thru-Bolt Assy Installed

SinceAug’09 to Sep’12 WEG Industries India limited, Hosur Senior Engineering Analyst – Assembly

Co-ordinate Greenfield Project Activities.

Coordinate with Machine Supplier for Machine Erection, Commissioning & Try out Activities.

Coordinate with HR team for recruitment activities.

Preparing weekly Project Status updating Reports.

Training given to all selected Assembly Manpower’s.

Handled all the activities and coordinating WII –Industrial Furniture’s (INR1.5 Cores).

Preparing the technical data sheet and procuring the Assembly machines, Devices, Fixtures Instruments, Tools etc., and other accessories required for the concern department.

Preparing the layout for the Assembly.

Define the Process & Selection of Device after project release.

Member of MFT from Industrial Engineering Department.

Training

I have been trained the complete process in Brazil for the Project for three months, manufacturing Process of High Voltage motors & Generators, Green Field project Handling methods and to implement the same in India

.

Since Oct ’08 to Aug ’09 Perlos Telecommunication & Electronic Component India limited, Chennai Production in charge – Assembly

Responsible for Day to day Operations(Production Management)

Material planning for next three days as per Plan.

On job training giving to New manpower.

Daily top three rejection analysis & CA taken for that rejections

OEE monitoring for critical machines.

MIS report preparation for weekly review meeting.

Coordinating with customer during audits.

Co-ordinate with Process engineering team for capacity enhancement activities.

Co-ordinate with New project team, for new projects. (we will ensure all CA &Poke yoka are identified in this Project)

Co-ordinate with Logistics team for dispatch activities.

Type & Product Manufacturing

M/s Perlos Communication & electronic Components India Private Limited is a leading Manufacturer for Mobile parts(Mobile Covers, some metal components & plastic decorations) and supplying products to Nokia, Motorola.

Mar’05 to Oct’07 Igarashi Motor India Ltd Team Management Leader – Operations

Leading a team of qualified technicians to achieve targets Monitoring & making process improvement changes via CFT meetings

Ensuring proper identification, Storage & handling of Materials in Shop floor.

Acting as a member of CFT and coordinating various activities like APQP, PPAP, Prototype development and new supplier’s identification.

Attending TS External Auditing, conducting internal system audit, preparing quality matrix for all products and monitoring SPC and CPK for the process.

Type & Product Manufacturing

M/s Igarashi motor India is an Japanese MNC leading manufacturer of Electronic throttle control motors, Wiper motors, Glass riser motors, Seat adjusting motors, Dc motors, Geared motors, High voltage motors and Armatures.

For over half a century, Igarashi Motor Sales has been dedicated to providing quality product and service to our customers. Since their establishment in 1952, they have grown to include DC motors, armatures, high voltage motors, and gear motors to supply a complete range of products to best meet our customer's needs. Motors are designed for a wide range of commercial and industrial applications, including power tools, home appliances and automotive and business equipment products.

Having branches at Japan, USA, German, China, and India. It is certified by TS 16949 and ISO 14000.

Significant Highlights

Played a key role in reducing the airfreight by 20% through effective planning.

Ensured Zero PPM for BOSCH & VISTEON Customers & Single digit PPM for other Customers.

Played a vital role in reducing the cost from Rs 5/- to Rs-2/-.

Enhanced operational efficiency through 5S activities on the shop floor.

Improved OEE to 80% from 56% for critical machines.

Pivotal in supplying products to the following key clients;

GM – US Plant, Ford - US Plant, Chrysler, Volkswagen, Fiat, Renault, Suzuki – Japan Plant, Mitshubishi

Bosch Power Train - German & US Plant, Visteon Power Train – US, China & Belfast Plant, MagnetiMerilli Power Train - Brazil, Italy &France plant, MIKUNI – Japan, Delphi – US plant and Arvin Meritor – US plant

Nov’02 to Mar’05 Syrma Technology (P) Ltd. Supervisor.

Leading a team of 200 employees in for handing the production operations.

Type & Product Manufacturing

Syrma Technology Pvt. Ltd. (Syrma tech) is a globally leading supplier and manufacturer of Passive RFID Tags, Precision Coils and Magnetic and belongs to Tandon Technology Venture. Located at Chennai, India, Syrma Technology has an illustrious track record of over 25 years within the group in high technology manufacturing. Precision Coils manufactured by Syrma tech are exported to Fortune 500 companies and find their application in Computer Hard Disc Drive and Computer Tape drives working in exacting environment

Significant Highlights

Increased the production from 35K to 65K through CELL concept

Improved the yield from 85% to 95%

Supplied the products to various key clients like PCB – Malaysia, Cowtek – Europe, Power Wave Technology, IBM – USA, TVS Electronics Ltd and Celetronics – India

EDUCATION

–B.E (Electrical & Electronics) from Dr. Sivanthi Adithanar College of Engineering, Manonmanium Sundranar University in 2002, Secured 76%

–Diploma (Electronics & Communication) from M.S.P.V.L Polytechnic, State Technical Board in 1999. Secured 87%

TRAINING PROGRAMS ATTENDED

–FMEA and MSA training program conducted by UL INDIA

–SPC and MSA training program given by PQ SYSTEMS

–Internal Auditor Training programs for ISO/TS.

–Certified as a Qualified Internal Auditor by TQM INTERNATIONAL PVT LTD.

–Trained in Special Monitoring charts via Fire Wall – BOSCH, TPP chart – VISTEON and A3 Format – DELPHI

–

COMPUTER PROFICIENCY

–SAP, C, C++, COBAL, MS-Office.

PERSONAL DETAILS

–Date of Birth: 17.03.1980

–Passport Number: K6712992

–Permanent Address: Flat No:2SC, Jain alpine Medows,Thiruneermalai Road,Chrompet,Chennai-600044,TamilNadu – India. Ph. Res. - +91-444*******

–Languages Known: Tamil, English (Read, Write & Speak)

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