Mechanical Engineer Manager

BABU GUNASEKARSAN

E-Mail: **********@*****.*** Mobile: +91-988*******

MANAGER – Machine shop

Industry: Automobile

To become a successful professional in manufacturing industry by exploiting fruitful, intensive experience gained in operations. Seeking Middle management position in a manufacturing organization, which can leverage abilities in operations. To be an innovative person in an economic way, orienting towards accomplishing goals of the organization

PROFILE SUMMARY

Focusing results to achieve goals professional offering 16+ years of successful career with diverse roles distinguished by commended performance and proven results

Last designation was Manager – Power train unit in ROYAL ENFIELD – Unit of Eicher Motors

Proven record of excellence in Production, Quality, and Delivery in new lines

Gained expertise in deploying process improvement tools in operations and new model components implementation

Gained functional expertise in managing the business operations with key focus on bottom line profitability by ensuring optimal utilization of resources

Experience in implementation of operations from Alfa to SOP, following SRK (Shoki Rudo Kantry) methodology to ensure quality of new product (HIMALAYAN & INTERCEPTOR)

Decisive leader with good interpersonal, communication and organizational skills

CORE COMPETENCIES

Machine shop operations (PQCDMSE)

Lean manufacturing

Productivity improvement

Working towards Management’s VISION & MISSION

Motivating team members to achieve goals

Leadership skills

PERSONAL DETAILS

Date of Birth : May 12, 1981

Present Address : #165. 2nd floor - 6th street, Viduthalai nagar, Kovilampakkam, Chennai – 600117(T.N)

Permanent Address : # 2. Trichy road, Chinthamanipudur(POST), Irugur(via), Coimbatore - 641103 (T.N)

COMPANY SCAN

Apr 2015 – DEC 2019 ROYAL ENFIELD (Unit of Eicher Motors)

MANAGER – Machine shop

Sep 2007 – Mar 2015 ASHOK LEYLAND.

Asst manager – Machine shop

(Transmission components)

Feb 2006 – Sep 2007 TVS MOTOR COMPANY

(One of the largest two manufacturing company in india)

Sr. Foreman – Engine assembly (STAR & VICTOR model)

June 2003 – Jan 2006 ROYAL ENFIELD (Unit of Eicher Motors)

Junior Executive – PED

KEY RESULT AREAS

Devising systems and processes for enhanced monitoring and control of resources and improved operational efficiency

Executing projects with respect to cost, resource deployment, productivity improvement and manpower planning to ensure timely completion of projects

Interacting with staff to implement and manage production initiatives with the goal of achieving excellence in plant operations

Directing Machine shop operations (PQCDMS)

Ensuring and monitoring TQM & Lean systems implementation

Developing budgets to improve Productivity & Quality initiatives

Ensuring compliance with workplace safety programs & organizing cross-training of worker teams for maximum production flexibility

Controlling product quality, rejection and rework rate.

Identifying areas of quality failures and taking appropriate steps to rectify them

Working with cross functional team to create/develop new ways to use resources – whether human / resources – most efficiently

Extending technical support to Current engineering team and Projects team for new model implementation

Accompanying Service team to support them on field issue & work with them on corrective action & preventive action (CAPA)

NOTABLE ACCOMPLISHMENTS

Mar 2015 – ROYAL ENFIELD, CHENNAI, TAMIL NADU

Established Engine components in-house production from the day one to 1500/day capacity in CLASSIC model, 200/day capacity in HIMALAYAN model, 250/day capacity in INTERCEPTOR model

Achieve and control Machine shop scrap level is less than 1000PPM

25% of Productivity improvement in CLASSIC model in house components from 1200/day to 1500/day(in nos)

15% of Productivity improvement in Machine shop by Man power reduction by lay out change & combined operations

Gained knowledge in new components production implementation and maintain less than 5000PPM in entry level by SRK system.

1Crore/annum cost saving project in INTERCEPTOR model – Elimination of Crank case Box assembly fasteners scrap(after 2times usage as per PD guidance) by preposed the component leak testing process before Box operation and One time used fasteners send to Engine assembly.

Cost saving project - Cylinder head component casting weight reduced by 280mg, Rs29/comp casting cost reduced and 2Crores yearly cost saving for 7Lakhs Classic volume per annum.

3VMC machines saving by combined the process in Clutch cover component (with in the desired cycle time) in CLASSIC model – Opportunity cost saving 1.5Crores.

Sep 2007 – Mar 2015; ASHOK LEYLAND – Unit 1, Hosur, TAMIL NADU

14% Productivity improvement by man power elimination by reduce operator fatigue by Introduce the component handling equipment

Tool cost reduction by reduce tool broken issue in Camshaft turning operation – 1.5lakhs / annum (Special Holders & turning inserts)

Cam shaft tool cost reduced Rs 24 per comp, by implement alternate CBN grinding wheel for LANDIS cam grinding machine (1.7 lakhs per annum)

Low oil Pressure - Internal customer complaint eliminated by provide the Orientation pin position sensor in Rear face oil hole drilling operation .

CAM, TC Noise – Internal customer complaint reduced by eliminating wrong alignment of work rest support in Cam grinding operation

Loose bur in long oil hole – Internal customer complaint eliminated by increasing the brush rod length in final washing stage

Component binding – customer complaint eliminated by improving the component handling method at final stage and stores

By modification of WIDMA – Gun drilling machine chip conveyor cutting oil consumption reduced by 20%, cost saving 1.2Lakhs / annum

Feb 2006 – Sep 2007; TVS MOTOR COMPANY, HOSUR, TAMIL NADU.

Setup time eliminated in Engine fire testing for STAR & VICTOR modles – 15mins.

Crank shaft bearing bore depth inconsistency complaint eliminated by introducing new boring tool (balanced boring tool) for STAR CITY model – CFT project.

Final washing operation eliminated in Crankcase component- Star model, by reduce components Millipore value after final washing @ machine shop, Cost saving Rs 3.5 lakhs / annum – CFT project

Body Leak checking process introduced in Cylinder head component,to reduce customer complaint

Cylinder head valve guide bore concentricity improved from 0.04mm to 0.015mm by tooling improvement, to avoid combustion leak – CFT project

4 Poka yoke system implemented to reduce engine assembly complaint from 1800 to 1200 PPM in Crank case component

June 2003 – Jan 2006; ROYAL ENFIELD, CHENNAI, TAMIL NADU

“ELECTRA” model chain case components in-house production implementation

“CLASSIC” new model components pilot production with existing setup.

Machine shop jigs and fixture spares replacement schedule implementation

Machine shop components tool cost reduction from Rs136 to Rs105, by Carbide tools regrinding system implementation

“BULLET” model Timing cover component cycle time reduction(10mins to 7.45mins), 20% productivity improvement

“ELECTRA” model Chain case cell 17% productivity improvement by cycle time(air cutting time) reduction

“Thunder bird” & “BULLET” Timing cover component machining contingency plan implementation by alteration of 4th axis.

Awards / certificates

Won the “Platinum” award for SMDE concept project(Royal Enfield) in “ABK AOTS DOSOKAI” institute, Chennai - June2017

Won the “Innovative & Impactful” award for “Uptime increases in Camshaft line” project(Ashok leyland) in “Automotive Engineering show”, Chennai – June2013

“6 Sigma Green Belt Course” Certification by ISI Bangalore - Aug2012

Won the “Bronze” award for EEI reduction project (Ashok leyland inter unit competition) – Feb 2010

ACADEMIC CREDENTIALS

2015 Bachelor’s Degree in Engineering (B. Tech) from Indra Gandhi Open University

2002 Diploma in Mechanical Engineering from State Board of Technical Education, Tamil Nadu

1999 Higher secondary, Coimbatore, Tamil nadu

1996 SSLC, Coimbatore, Tamil nadu

Note:

Pursuing “Master of Business Administration” (3rd sem) in Anna University - Distance Education,

Chennai,Tamil nadu.

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