Head of Manufacturing Operations

SUMMARY

Exposure to working across automotive OEMs and Industrial products manufacturing. Having more than 23 years of experience in the area of Manufacturing & Manufacturing Engineering. Skilled at setting up green field projects, knowledge transfer and production efficiency enhancement & cost management through process re-engineering.

Trained in more than 7 countries on major technical and managerial programs.

PROFESSIONAL ABRIDGEMENT

TRAININGS

IATF16949 ISO14001 OHSAS 18001 APQP PPAP PFD & FMEA MSA 7QC SPC Danfoss Lean Leadership (DOLL) Lean Manufacturing Techniques Toyota Production System Leading others Situational Leadership (SL-II)

GLOBAL VISITS

oKorea for new press tools tryouts at supplier end in 2004; twice in 2008 for radiator and inter cooler assembly and testing machine tryouts & validation at supplier ends.

oChina in 2013 & 2016/17 for attending leadership program & training on Lean manufacturing techniques.

oUSA in 2008 for training in Radiator, CAC, and Oil Cooler manufacturing process and CAB furnace tryouts & final sign off.

oGermany and Italy in 2009 & 2010 for conducting pre shipment Inspection at supplier ends (Fin Stamping Press for Oil Cooler).

oMexico and Poland for knowledge transfer and facility shifting in 2012 and 2014 respectively; also trained in pressure controls & Industrial valves manufacturing processes.

AREAS OF EXPERTISE

Implementation and Maintenance of Production and Quality System – Well versed with IATF / TS16949, ISO14001, OHSAS 18001; Thorough knowledge in developing & maintaining Process Flow Diagram, FMEA, Control Plan & Manufacturing Instruction Sheet, etc; conduct risk assessment and preparation of necessary contingency plan & operation control plan.

Adept in the making proto samples as per the design requirements; well versed with APQP, PPAP, and PSW activities.

Skilful with Lean manufacturing practices – Value Stream Mapping / Material & Information Flow Analysis, Kanban / Single piece flow, cellular production, Poka yoke, process automation, Kaizen, 3C5S, etc.

Understanding of the logic of engineering drawings & principles and resourceful in preparation of estimates / quotations & reports for stamping parts, casting parts, machining parts, assembly parts, etc.

Extensive experience with conventional equipment such as press & progressive press tools, lathe, drilling machine, surface Grinding, TIG & MIG welding and SPMs such as CAB Furnace, Helium leak testing, bending, and several customized assembly & testing processes.

Rich experience in successful completion of Green filed projects; good in Planning, budgeting, capacity analysis, equipment selection, ordering, etc; Expertise in preparation and Implementation of plant layout, Installation and commissioning of equipment, process validation & optimization.

Well versed in setting up warehouse facility, Identifying & nominate able distributors / wholesalers and introduce robust supply chain for any new product / organization.

SIGNIFICANT ACHIEVEMENTS

Organization

Role Played

Gain

Sanhua Climate & Appliance Controls Group Co., Ltd

(Jan’15 – May’17)

1) Derive business strategy & laid out aggressive plan for 2025.

2) Worked out macro & micro level plan and taken substantial steps to meet the magic figure of 100 crore Indian rupees (16 Mil. USD) turn over by 2025.

1) Pave way to penetrate Chinese brand (Sanhua products) in India.

2) Won turn key businesses with major OEMs like Emerson, Tecumseh, Schneider Electric, Khan Controls & others.

Danfoss Industries Pvt. Ltd., Chennai

(Jan’12 – Dec’14)

1) Established production line for Filter Drier and Pressure Control by facilitating smooth knowledge transfer from plants in Mexico and Poland in just 6 months.

o This also involved timely installation & commissioning of key machinery and equipment such as plasma welding, brazing furnace, degreasing, helium leak tester and several assembly & testing equipment; completion of product & process validation to ensure timely instigation of manufacturing.

2) Localized > 80% of components used in filter drier, Industrial valves & pressure controls.

3) Outsourced key processes related to manufacturing of Filter Driers and Painting Processes.

1) Started supplying to pan India well before the original plan.

2) Huge savings of 20% in the overall product cost by FY2013.

3) Reduction of manufacturing cost by 15% & significant Improvement in the overall EBIT by 12%

Modine Thermal Systems Pvt. Ltd., Chennai

(Jun’08 – Dec’11)

1) Developed robotic welding machine to weld Charge air cooler / Inter-cooler locally in Chennai.

2) Designed & developed Radiator and Inter cooler assembly machine & necessary fixtures locally in Chennai.

3) Played vital role in preparation of standard estimations / quotes for major OEMs.

1) Manufactured & delivered in quick span with a cost of around 40% of its original import price (from Korea or Germany), Cost saving of INR 75 Lakhs.

2) Cost saving of INR 1.5 crores.

3) Helped in acquisition of new businesses from major OEMs within 2 years from the start of plant operations.

Visteon India Pvt. Ltd., Chennai

(Jun’98 – May’08 )

1) As a member of several special purpose team, played key roles in "performance increase for HVAC system" and "solving crucial tube erosion problem for inter cooler".

2) Conversion of traditional torch brazing process of heater core & tubes into automatic CAB brazing.

3) Conversion of manual flux application process to automatic fluxing process.

4) Reduction of raw material thickness & width of evaporator assembly plates in the stamping process (Progressive die).

5) Completed projects exceeding $6 million for designing, installing & commissioning of brazing furnace and 400 ton press.

6) Ergonomically redesigned the layout for Climatic Control System plant.

1) Reduction of rejection rate from 20% to 2%

2) Reduction of 2 man power and increase in productivity by >300%

3) Reduction of 2 man power and ensures uniform & stabilized brazing process, led to decrease in rejection rate by 5%

4) Cost reduction of 11% in the overall product cost price.

5) Completion of project well ahead of the targeted date & started full-fledged production.

6) Saving of 15,000+ sq.ft area, later used for new production line for compressor.

CAREER CONTOUR

Micro-Tech CNC Pvt Ltd June’19 Onwards

Headquartered in Hosur, 250 Cr.INR turn over company into manufacturing of high precision machining,

sheet metal, heavy and medium engineering fabrication since 1989. Presence in India & Australia.

Plant Head (Manufacturing, NPD, Application Engineering, Logistics, Quality, Customer Support, P&L)

Taken up an assignment to establish the new facility in Chennai.

Implement standards & systems and ensure all the basics are in place.

Identify right talents, provide training and build robust & versatile organization.

Implement QMS & lean manufacturing practice.

Explore new business opportunities with existing & new customers; Increase sales & cash flow.

Responsible for construction of plant, buying of capital equipment and bring safe & world class working environment.

Efforts to bring in the world class system, discipline and culture across the organization.

United Handss (P) Ltd, Own Consultancy Services June’17 – May’19

Started Consultancy services based at Chennai, Tamil Nadu

Design & Development of sheet metal components, welded / assembled parts.

Design & development of Special purpose equipment & Fabrications.

Product selection support to refrigeration & air conditioning manufacturers.

Supply chain Orientation & Cost reduction projects.

Helped Organization in Implementation of QMS, Production system and Lean Manufacturing Techniques.

Profit enhancement and drive for sustainable growth.

Zhejiang Sanhua Climate & Appliance Controls (India Operation had been closed by May 2017) Jan’15 – May’17

Headquartered in China started in 1984; 3.5 Billion USD worth of business; 28k talented employees are working; having global presence (China, USA, Europe, Australia, Singapore, Thailand, India and other Asian countries)

Head Operations (Sales & Marketing, warehouse & Logistics, Application Engineering, Customer Support, P&L)

Laid out a fresh & permanent road for Sanhua commercial products division in India;

Identify and nominate able distributors / Wholesalers across pan India; have a complete market study and fix optimum price for India market and thus increases the acceptance of Sanhua among India customers.

Setup warehouse facility and laid out robust supply chain network for India market.

Danfoss Industries Pvt. Ltd., Chennai Jan’12 – Dec’14

Headquartered in Denmark, Global producer of components and solutions. Products used in areas such as cooling food, air conditioning, heating buildings, controlling electric motors & powering mobile machinery

Senior Manager, Production / Operations (Production, PPC, Process Engg, Maintenance, Quality, P&L)

Managed a team of 150 employees comprising of managers, engineers and BCWs.

Implemented Danfoss Production System & QMS; Established Chennai plant as the most profitable facility of Danfoss across the world by optimizing the overall operating cost of the plant.

Mentored the team to develop many SPMs and fixtures, such as connector expansion / reduction equipment & tools, box riveting and flaring M/C & tools and helium leak test equipment, locally.

Identified key talents / future potentials (potential future leaders of Danfoss) & mentored them to channelize their thoughts / enhance their skills through education, training, workshop, etc.

Modine Thermal Systems Pvt. Ltd., Chennai Jun’08 – Dec’11

Headquartered in USA, operating since 1916; Committed to design, manufacture and test heat transfer products for a wide variety of applications and markets such as automotive, off-highway, truck, engines and building HVAC.

Deputy Manager (Production, PPC, Process Engineering, Quality, P&L)

Established a new production facility at Chennai with end-to-end responsibility from facility planning, plant layout preparation to machine installation & commissioning well within the stipulated time period of 8 months.

oThis also involved ordering of new equipment, recruitment and training, validation & optimization of key processes such as thermal degreasing & fluxing, CAB furnace, core builders, fin rolling & stamping, helium leak tester, etc and facilitating new supply chain practices in the facility.

Ensured establishment of stringent quality requirement that led to export of parts to Renault Nissan Corporation within the stipulated time of 6 months.

Involved in supplier selection across all stages including floatation of RFQs, comparison of quotes, finalization of supplier, and issuance of purchase orders. This also included in-personal visits and inspection of supplier’s facilities across India, Italy, Germany, Korea and the USA.

Served as Programme Coordinator & drive APQP process pertaining to several OEM’s Viz. Ashok Leyland, Mahindra & Mahindra, Tata Motors, Renault Nissan, Daimler, etc.

Visteon India Pvt. Ltd., Chennai Jun’98 – May’08

Headquartered in USA, leading global automotive supplier involved in design and manufacturing innovative climate, interior, electronic & lighting; a fortune 500 company, Visteon employs 18,000 people in 21 counties across the world.

Senior Work Group Leader: Production

Led and guided a team of 250+ (Engineers, Supervisors, Technicians & Operators) to manage the operations of the organization; responsible for entire manufacturing line which involves several key processes viz. degreaser, 300 & 400 ton press and progressive press tools, core builders, fin forming, CAB furnaces, helium leak testers and final assembling of radiator, HVAC, condenser & heaters which goes to passenger vehicles.

Played a special role as Supplier Technical Assistance & SCM person for a short while and successfully outsourced some key processes, which involved

oSupplier selection & validation; sample approval and final release.

oBuilt sufficient stock at in-house & vendor place; Train vendors in all the processes / equipment and successfully done the knowledge transfer; smooth transformation of equipment to supplier end (press & press tools, bending machines, leak testing machines and several assembly machines).

Kali Material Handling Systems Ltd., Kumbakonam Jan’97 – Jun’98

Kali BMH Systems is pioneer in manufacturing of Conveyor Idlers and Pulleys; operating since 1950. Catering to the bulk material handling requirements of major super thermal power plants, mines, ports, cement and steel plants and other ore handling systems.

Production Supervisor

Involved in various quality improvements activities, some of the significant activities are

oOptimization of the housing blank size, which led to reduction in machining time & the overall housing cost.

oDesign and implementation of dust seal cover for the idler rollers, which led to drastic improvement in roller performance and life time.

EDUCATION

2013 TAMIL NADU OPEN UNIVERSITY Chennai Masters of Business Administration (Operations)

2006 MADRAS INTITUTE OF TECHNOLOGY, ANNA UNIVERSITY Chennai

Bachelor of Engineering - Production Engineering

1996 STATE BOARD OF TECHNICAL EDUCATION Chennai

Diploma in Mechanical Engineering

PERSONAL Date of Birth: October 17, 1977

K.VENKTESH

No. 2, Tholkappier Street Extn, Nemilicheri, Chrompet, Chennai – 600044 ***********@****.** +91-733**-*****

Production Management

Implementation of PMS

PPC / Supply Chain Management

Facility Setup & Project Management

Effective utilization of resources

Continual Improvements

Training & build versatile team

Develop mutual trust & strongly bonded team

Engineering & Quality

Manufacturing / Process Engineering

Implementation of Maintenance system

Implementation of QMS

Product Development & Proto sampling

Supplier evaluation & management

Handling RFQs & drive APQP process

Drive Lean Manufacturing Techniques

Profit Enhancement

Strategic Planning

Capacity Improvisation

Budgeting & Cost Controls

Drive cost reduction projects

Handling P&L

Fund Management

Achieve sustainable Growth

Specialized in the areas of manufacturing Heat Exchangers (Radiator, Condenser, HVAC, Inter cooler / Charge air cooler), Industrial components viz. filter drier, Pressure controls, Industrial valves.

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