Engineer Manager
Resume:
JOB OBJECTIVE
To be a part of motivated team to lead a successful & challenging career in a competitive environment that brings out my inherent knowledge & skills, which stimulates both my personal and Organization’s growth.
PROFILE SUMMARY
Result oriented professional with 16.0 years of comprehensive experience in managing the entire gamut
of operations related to Production and New Product & Process Development of casting/Forging, Machining,
Heat treatment, Assembly, stamping, Welding, and Testing process.
Ability to find out RFQ product selling price based on customer inputs like drawings and SOR. Good Exposure
In preparing feasibility report/Presentation and managing technical discussion with customer.
Expertise in managing diverse range of activities such as new plant development, process & equipment selection,
New projects & capacity planning, process control with product validation, cost management & quality assurance.
Adroit in managing plant operations with accountability of maximising plant profits and minimizing expenses.
Proficient in developing & streamlining systems with proven ability to enhance operational effectiveness and
Meet operational goals within the cost, time & quality parameters.
Knowledge in DAP, Poka-Yoke, Kaizen, APQP, PPAP, DFMA, PFMEA & MFMEA, MHE, ROBO.
Experience in Value engineering and value analysis & Reverse engineering of components.JIT,FIFO,Kanban,
VSM & LPS, Hydraulic and Pneumatic circuit design with Low Cost Automation.
Deft in implementation of quality standards such as ISO,TQM,TPM,QS 9000,IATF 16949,OSHAS,5S,
Process audit and Customer audit.
An effective team leader with strong analytical, planning, troubleshooting and problem solving skills using
7 QC tools & Management tools, 6 thinking Hats & DOE tools,8D report preparation.FTA/Function diagram,
Six sigma concept, MSA & SPC.
Demonstrated excellence in challenging Deming Grand Prize in 3 organizations. (WABCO, RBL & SFL)
Ability to identify and select supplier based on technical and financial evaluation.
Well versed with AutoCAD 2014,NX 10.0, 2014, SAP – (MM & PP), PLM & PDM, MS Office 2013,
Windows and Internet Application.
ACADEMIC PROFILE
Course
Name of the Institution / Board
Year of Passing
Percentage of Marks
M.Tech -Manufacturing Management
Birla Institute of technology and science,/
BITS Pilani, Rajasthan
2018
7.02
B.Tech - Mechanical
Sri Venkateswara College -Tiruvannamalai /
JRN Rajasthan Vidyapeeth University
2012
63
Diploma-Mechanical
Vignesh Polytechnic-Tiruvannamalai,/
Directorate of Technical Education (DOTE)
2004
89
INDUSTRIAL TRAINING UNDERGONE
Attended workshop on GD & T, APQP, PPAP, PFEMA,CONTROL PLAN, Poka Yoke,Mistake Proofing, MSA,SPC and Documentation.
Attended internal training program for lean manufacturing system.(3m analysis, waste elimination, VSM,VAVE,TPM,JIT,FIFO,Kanban,5s & Hydraulic and Pneumatic circuit design with Low Cost Automation)
Problem Solving Tools (7QC Tools, 8D & Why Why Analysis,DOE,6 thinking hats)
Attended workshop on TQM Principles and TS 16949 Requirements, EMS-ISO 14001:2004
Attended internal training program software skills (MS-Office,Outlook & MINITAB 16, PLM,SAP, MS-Project)
First Aid Training and Fire and Safety.
Personality development of People management and Team building.
ORGANIZATIONAL EXPERIENCE
Company Name
/Location
WABCO INDIA Ltd (Ex.Sundram clayton) /Ambattur-Chennai
Rane Brake Linings (RBL) /
Ambattur-
Chennai
Sundram Fasteners Ltd (SFL) /
Mahindra City -Chennai
Magal Engg Tech Pvt.Ltd /
Oragadam-Chennai
Total
(Yrs)
Period
Jun’04 – Sep’10
Sep’10 – Oct’14
Oct’10 – Aug’19
Sep’19 –Till date
No of years’ experience
6 Yrs
4 Yrs
5 Yrs
1 Yr
Designation
Trainee to Diploma Technician Engineer
Engineer to Senior Engineer
Senior Engineer 2 to Assistant Manager 2
Manager-HOD
Department
Production Engineering Department (PED)
Facilities Planning-Corporate
Production Engineering Department (PED)
Process Design Department
Products
Air compressor, Valves,
Actuators
Brake linings, Disc pads, Clutch & Railway brake
Powertrain components
,Transmission shaft
Con rod, manifold,Thermo start,Jack,Cable &
Aerospace parts
RM Knowledge
Alumimum,Steel,
Cast Iron, Plastic,Rubber,Brass
Friction material, Steel & Aluminum,
Steel & Cast Iron
Steel, Cast iorn,Plastic, Rubber, Brass &Wax
Set up
Machine shop, Assembly, Plating Shop, Testing lap.
Press shop, Assembly, Finishing line.
Machine Shop, Assembly, Heat treatment, Testing lap
Machine shop,
Assembly, Press, Welding, moulding
Reporting to
Manager-NPD
Manager-FP
GM-Engineering
GM-Plant Head
Reportee (Nos )
-
-
2
9
Core competencies
Process Design
6 Yrs
4 Yrs
5 Yrs
1 Yr
16.0
Costing
-
4 Yrs
5 Yrs
1 Yr
10.0
New product development
6 Yrs
4 Yrs
5 Yrs
1 Yr
16.0
Sourcing/Vendor/
Supplier Development
6 Yrs
-
5 Yrs
1 Yr
12.0
Manufacturing Engineering
6 Yrs
-
5 Yrs
1 Yr
12.0
Business development
-
4 Yrs
5 Yrs
1 Yr
10.0
Project/Program Manager
-
4 Yrs
5 Yrs
1 Yr
10.0
Area of Strength
Forging / Casting /Moulding
16.0
Machining (Turning, Milling, Gear Forming. Gear Cutting,Gringing,Polishing,
-
12.0
Sheet Metal Stamping
-
11.0
Assembly (Tigthen,Riveting & Welding)
16.0
Surface treatment -Plating & Hardening
-
-
11.0
Hydraulic & pneumatics press
16.0
Plant & Equipment layout
16.0
Machine Building
-
10.0
Resource Optimization
16.0
Problem Solving
16.0
Testing
16.0
Part life validation and analysis
-
10.0
CORE COMPETENCIES
New Product Development & Projects
Determining the RFQ costing for sequence of Operations, Machine, cycle time, and output per hour, machine hour rate and cost per component.
Preparation of Feasibility report and raise technical queries to customer.
Discussion with customer about RFQ costing technical details & Time plan.
Preparation of Project planning & CAPEX data.
Preparation of all engineering documents (PFD, Control plan, PFMEA.etc…),
Tooling, Work holding design and Machine / Facility selection for NPD parts.
Conducting part validation test and get approval from customer.
New product routing & material master creation through SAP.
Development of proto sample at supplier end and in-house as per APQP.
Project planning and on time execution with the given CAPEX target.
Conducting production trial run, run @ rate & PSW approvals.
Packaging design finalization and validation.
Project Management for the entire Product life cycle, which includes RFQ, Sample development, Pilot lot, Ramp up & Productionisation.
Planning and execution of validation and verification tests as per plan to meet the customer schedule and report preparation.
Manufacturing Engineering
Developing & implementing processes for capacity expansion; Lean manufacturing, Productivity Improvements,
Process time optimization, rejection & consumable tool cost reduction.
Preparation & release of engineering documentation and Engineering change management systemization &
On-time implementation.
Reviewing existing processes and re-designing the same to enhance operational efficiency.
Improve OLE thro Time study, Motion study, Line balancing, Layout optimization, SMED & MFMEA.
Taking caring of Continuous Improvement project and acts like a Methods Engineer to monitor the
Improvements through PDSA & PDCA.
Implementation of Poke Yoke System and works to achieve Single Piece Flow & Cycle Time of Flow
in machine shop & Assembly.
Understanding quality issues from customer`s perspective and improving customer satisfaction.
Preparing Standard Operating Procedure (SOP) for customer Drawings.
Improve handling of materials to reduce component damages in-house.
Involved in VA/VE and localization activities. Optimize RM Consumption to improve yield.
Implementing cost saving measures to achieve substantial reduction in terms of production cost, and energy.
Monitoring the machining / Assembly process in shop floor for NPD and stabilizing the process for regular
Production.
Ensuring safe work methods & use of safety equipments by the operators.
Vendor development & Sourcing
Identification and selection of supplier based on technical, financial, capacity and technical capability evaluation.
Identification and supporting machine-building vendors for reverse engineering of existing available facility, new concept SPM, Work holding devices and material handling equipment.
Identification of sub contract sources for Gamma part submission.
Supplier readiness review in line with customer milestones & PPAP audit with run @ rate trials.
Assess Technical support and train vendors on new product development and regular production.
Highlights:
Magal EnggTech (1 Yr)
150 parts RFQ cost estimated and offered to customer in Automobile, railway and aerospace segment.
Proven Mahindra D22 con rod in new line and PPAP approved by customer.
Successfully duplicated new assembly cell for thermo start.
1.5D con rod cutting tool cost reduced from Rs 45 to Rs 39.
Development in progress of BI-VI project con rod to Sang song export customer.
Proven and implemented in house stamping process of maruti thermo start cover.
Successfully installed and completed the MIG welding to Jack assembly.
Sundram Fasteners Limited, Chennai (5 Years)
Total 450 parts costing worked out and shared to various 17 customers on time.
Prepared Feasibility report and raised technical queries to customer.
Worked with CFT and completed technical discussion with customer -112 parts
11 NPD proto sample developed at supplier end and in-house within scheduled time ( Max 6 month/part )
Playing a key role in new projects. Already 11 projects completed in existing plant and 2 projects for new plant.
Improved Part life cycle by redesign and re arrangement of process – 3 parts
Reduced rejection percentage from 3.3 to 1.4 within 6 months in turbine shaft line.
Tool cost reduced from 3.7 to 3.1 per part by revising the dresser geometry in grinding operation.
Worked and completed ramp up projects 2 /year.
Proven the 8L45 model turbine shaft line machine on time with purchase order cycle time
Successfully installed and proved the automated bush pressing assembly and reduced cycle time from 47 sec to 21 sec.
Successfully implemented and played key member in unmanned forging plant project.
Demonstrated excellence in challenging Deming Prize
Rane Brake Linings, Chennai as Senior Engineer – Facilities Planning (4 Years)
Holds the distinction of developing new facilities for enhancing capacity of all plants and for meeting requirements of new products.
Played a key role in setting up a new manufacturing plant for PCBL with Asset Turnover Ratio of 1.78.
Instrumental in reducing cost from Rs. 36.7 Crores to Rs. 32 Crores (13%) through optimisation of plant layout and by reducing the building size from 80Mx40M to 60Mx33M.
Drove expansion of capacity by introducing concept of Scale of Economy Study, Blue Print and JES
Attained significant reduction in:
oInvestment, by leading a CFT, thereby achieving RBL goal of 27% RONA
oPotential failures / breakdowns in equipment by introducing Machine FMEA
Demonstrated excellence in challenging Deming Grand Prize by RBL.
Total 13 projects completed in 3 different locations.
Strengthened specification finalisation and inspection of machine, through introduction of systems like Interlock Matrix, Process Sequence Chart and Abnormality Checklist.
Reduced new machine complaints from 31% to 19%
Reduced rejection rate for PCBL manufacturing from 9000 PPM to 3500 PPM.
Developed one more supplier for disc pad back plate and brake shoe.
WABCO INDIA Limited, (Ex. Sundram Clayton) Chennai (6 years)
One of the core members in New Product Develop team and completed 8 NPD projects.
Successfully introduced auto-riveting facility for valve plate riveting assembly– Out-put increased from 20 nos per hour to 35 nos per hour.
Successfully introduced supporting arm with runner in compressor assembly station to eliminate customer complaints and automatic test rig for leak checking in DDU assembly.
Successfully introduced hydro-pneumatic press for compressor bush pressing.
Around 67 poka-yoke introduced in assembly line.
Improved OLE from 67 to 78% through 3M analysis.
Eliminated de bottleneck operation in various lines by time study and line balancing,ECRS method.
Reduced rework percentage from 3% to 0.6% in R6 valve assembly line though 6 thinking hats method.
Successfully initiated and implemented Gravity die casting to Pressure die casting for DDU Body (Casting) - Output increase from 38nos to 52 nos.
Developed 82 child parts (casting cum machined parts / Metal / Rubber / Plastic) from various suppliers.
Combination cutter introduced in DDU Body VMC Machining -cycle time reduces from 88S to 48S.
PERSONAL INFORMATION
Date of Birth / Age : 2nd July 1985 / 35 yrs
Permanent Address : No. 42. Kosamada St, Near Anna Salai, Tiruvannamalai-606601
Marriage Status : Married
Languages Known : Tamil & English
Passport No : U4537307
Declaration
I consider myself familiar with Mechanical Engineering Aspects. I am also confident of my ability to work in a team.
I hereby declare that the information furnished above is true to the best of my knowledge.
Place: Urapakkam-Chennai yours truly,
Date: Ashok Kumar R
NNnoa Negotiable
ASHOK KUMAR.R - M.Tech Current CTC - 12.43 LPA
Manager – 16.0 Yrs – Costing,NPD & MED. Expecting CTC - 14.50 LPA
Mobile: 979******* / 967-***-**** Notice Period - 60 Days
E-Mail: **********@*****.***
Address: Flat No 4- 4A Praia Nagar, Urapakkam Tea kadai bus stop, Chennai – 603 210.
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