Manager Quality

R. Krishna Prasad

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

Aluminum die casting & processing, Operations control, Policy planning & deployment, Percolating the practice of TOYOTA MANAGEMENT SYSTEM (TPS) & TQM with strong Daily Work Management. Alloy manufacturing, Improved Metal recoveries & Energy savings, Management Representative for TS 16949, New Product Development & Testing, Customer Relationship Management (CRM), Vendor Development and Raw material sourcing

Offering an impressive experience of over 25 years in Aluminum die casting & processing for the Automobile Industry

Profile

A Decisive leader with proven acumen in leading a manufacturing unit in business uncertainties. With a focus on bottom line profitability by ensuring optimal utilization of resources within the set parameters and operational analysis. Managed modern business systems and ventures in challenging and diverse environments.

Highly experienced Metallurgist with a gratifying career span of over two decades in the areas of Manufacturing of aluminum die casting parts, Detailed Engineering projects & its Execution, Process Development & Control, Quality Assurance, Quality control & Quality Systems, Product Development and Testing, Expanding new Business growth opportunities.

Extensive experience in meeting the in-house quality requirements with close process controls of aluminum die casting products supplied to the Automobile OEM’s with the desired quality levels.

Key member in all New Product Development, Implementation of controls on Special processes and product testing

Team leader for raw material sourcing, supplier development & supplier audits for downstream integration and operational viability

Demonstrated capabilities in heading the manufacturing unit for strategic development and overall Quality functions of the Die Casting Division, Metallurgical Processes, etc., Adept in identifying problems, formulating tactical plans, initiating change and implementing effective process controls.

Well versed with quality systems in the Automobile Industry coupled with proficiency in executing projects involving Alloy Development, Waste Elimination, Energy savings, TQM, TPS, etc.,

Career Milestones

Vice President – Manufacturing in KOSEI MINDA Aluminium Pvt.Ltd. Chennai. In-charge of overall operations and new Business development.

In-charge of overall Engineering & Quality functions with focus on New product development

Head of Strategic planning and implementation of energy saving projects, expanding business of the NABL accredited lab into new ventures and effective QMS implementation in Sunbeam Auto Pvt. Ltd.,

Pioneered New Business ventures, Process efficiency improvements and energy savings to new heights in ASK Automotive (P) Ltd., The unit became a profit making centre in one year of operation

Successfully turned around quality and operations performance at Sundaram Clayton Ltd. and transformed it as a global destination for Aluminum Die Casting parts

Actively involved in devising, designing, construction, commissioning & maintenance management of entire Metal Management section in the Division

Successfully completed a Six Sigma Project titled “Low Elongation in Heat Treated Castings for Cummins Turbo Technology”, U.K., as Team Leader - Member of Six Sigma project with Cummins Turbo Technology, U.K.

The project was identified as one of best project completed and was appreciated by the Chairman

Introduced New Alloy for FORD and the same was presented as a case study to CII - the product won the first Prize in the Southern level competition for Managers.

Pivotal in the introduction of new process technology in Die Casting of aluminum alloys which won the first prize in the CII competition for Managers in the Southern level competition for Managers

Won the All India first Prize for Best Scanning Electron Microscope (SEM) exhibition at the National Metallurgical Day (NMD) Celebrations of the Indian Institute of Metals (IIM), at Calcutta during successful association with INDAL.

Management representative for TS 16949 in Sundaram Clayton for 3 of its plants for more than 10 yrs

Spearheaded the R & D Centre of the Indian Aluminium Company at Belgaum on process improvements in the field of casting and rolling operations.

From 1st Jan 2019 : Metallurgical consultant on process improvements in the Aluminum industry. Providing solutions on improving process efficiency in casting, rolling and furnace operations. Structured problem solving approach to shop floor issues.

Professional Experience

VICE PRESIDENT From 4st April’ 2016 till 31st Dec’ 2018

KOSEI MINDA ALUMINIUM PVT. LIMITED

CHENNAI

Spear headed the project to expand the capacity of delivering 75,000 wheels per month from 60,000 wheels per month. A project which was completed in a record time of 6 months from conceptualization to SOP

Achieved the lowest rejection rate in casting of 3.5 %. A new benchmark in the KOSEI group.

Developed the 18’’ wheel for TOYOTA thru’ the new flow forming process technology. The first of its kind in India.

GIVEN ADDITIONAL RESPONSIBILITY OF QUALITY & ENGINEERING from 1st April’2018 till date

Successfully migrated to IATF 16949 from TS 16949

Reduced leak rejections to < 1 %. A new record in the KOSEI group.

Introduced 11 new products in a span of 8 months. A new milestone in KOSEI, Chennai plant.

Demonstrated speed and capability of delivering new products from Design to SOP stage.

Secured Business sustenance for the next 5 years and beyond

SENT ON DEPUTATION to KOSEI, THAILAND during Dec’18 to improve metallurgical process of operation.

Improved metal recoveries by 3 % with an improved bottom line of 8 million / year.

Brought in process changes and reduced rejections due to metal quality from 3 to 1 %

GENERAL MANAGER : PRODUCTION From 4th April 2016 to 1st April 2017

Spear headed the task force in bringing in the company to adopt and follow the Toyota Production System (TPS)

Brought in a paradigm shift from an unstable to a stable operating system in all functions

Brought in a cultural change in operations and quality control with the involvement of all operators

Nurtured the spirit of team building and built in 3 levels of leaders in all operating functions.

Speed of action and elimination of delivery failures to customers was the key turnaround

Zero ppm at customer end

High recoveries of 97 % in chip melting with a significant contribution to the bottom line

GENERAL MANAGER : QUALITY From 1st December 2014 to 10th March 2016

SUNBEAM AUTO PVT. LTD.,

GURGAON, HARYANA, India A UNIT OF MUNJAL GROUP

Key responsibilities :

a)Heading entire Quality function of High Pressure Die Casting and Gravity Die Casting activity of the entire plant

Reduced overall process rejections by 2 % in High pressure die casting

Improved timely PPAP approval and PSW sign off by 30 %

b)Heading Melt shop for 3 plants as part of Strategic planning. Spearheading all metal quality improvements, energy reduction / cost saving projects having a direct impact on the bottom line

Improved melting efficiency by 7 % & Improved metal recovery by 6 %

Contributed to bottom line saving to the tune of 3 crores

c)Heading the QMS activities for effectiveness of TS 16949 systems

Successfully completed the Re-certification audit for TS 16949

Introduced Quality month celebrations. This was the first time such a month long event was celebrated

d)Heading the NABL accredited lab having state of the art facilities and operating as a separate business centre. Improving business potential and foraying into new areas of testing

Solution provider in the field of Aluminum processing, Energy conservation & QMS : From Aug’14 to Nov’14.

GENERAL MANAGER : OPERATIONS & QUALITY From Nov’13 to Aug’14

ASK AUTOMOTIVE (P) LTD.,

KOLAR, BANGALORE

Operational head for developing new business and improving overall plant efficiency

a)Quality head for all in - line process quality control, process improvements, quality systems and new product development of Aluminium die casting, machining, painting and assembly.

Brought in TVS and YAMAHA motors as new customers with the introduction of new products and broke the monopoly of catering only to HONDA motors. Increased revenue of over 2 Crores per annum

Increased monthly sales from 18 Cr to 25 Cr in 6 months of taking up the assignment

Increased HPDC overall efficiency from 69 % to 74 % in 6 months of taking up the assignment.

Reduced diesel consumption in melting furnaces from 80 lts / ton to 50 lts / ton in 6 months after taking up the assignment. This is a new milestone and is considered best in the entire Asian region. Saving of Rs.9 lakhs / month

Reduced customer end rejections form 3.5 % to 1.5 %

Reduced overall internal rejections from 15 % to 7 % in HPDC process

ASSISSTANT GENERAL MANAGER (AGM) Quality Assurance. From Jul’99 to Oct’13

DIE CASTING DIVISION

SUNDARAM CLAYTON Ltd., CHENNAI. A unit of the TVS group

Successfully directing 180 members from Production & Quality towards achieving both Production & Quality targets

As Department Head- Quality & Customer Support Group

Management Representative (MR) to sustain QMS and get certified 2 additional plants for TS16949 quality system.

Installed a state-of-the-art Testing Facility for executing all Metallurgical, Metrological and Radiography testing activities.

Achieved bottom line profitability & cost savings by implementing Six Sigma Projects.

Reduced customer end rejections to PPM level in machined parts with Cummins, Vovlo, Visteon, Honda, Hyundai etc.,

Achieved < 1 % rejection in all customer end as cast parts which included regular and new products for 3 years

Developed practical techniques to identify blow holes in pressure die casting and improved precision of computer simulation thereby reducing rejections.

Achieved zero porosity rejections for safety critical parts of VOLVO and set a new benchmark in SCL in producing similar products

Team leader for Raw material sourcing which paved way for global sourcing with desired quality and cost

Provide necessary solutions as part of Customer relationship Management (CRM) to all customers and also suppliers.

As Senior Manager – Operations

Recorded the highest production and sales of the Gravity die casting section

Moved up the business from a captive operation to a global player by bagging orders from FORD and VOLVO.

Maximized yield of products from 75% to 95 % for CUMMINS on turbo parts

As Senior Manager - Metal Management

Recorded lowest ever consumption of fuel of 60 litres / ton of melting and operational efficiency in the industry by setting new benchmarks and thereby contributing in operating profits.

Reduced melting loss from 15 % to 3 %. This contribution has led to savings of 50 million.

Improved operational efficiencies by reducing a total of 97 personnel with improved outputs year on year

As Project Manager

Set-up the Melting & Alloying Facility along with the Material Testing Facility and successfully managed re-vamping the melting section.

Successfully introduced new technology of melting furnace which significantly enhanced recoveries and bottom line reduced material losses. This received the beast company award for the year

Assisstant Superintendant From May1993 to Jun1999

Indian Aluminium Co. Ltd., (INDAL)

Belgaum

One of the largest producers of Alumina and Aluminum under collaboration with ALCAN (Aluminum Company of Canada), now under the flagship of Aditya Birla group of companies - HINDALCO.

Selected Accomplishments

Executed a project in collaboration with ALCAN, U.K. to improve efficiencies in 7 micron foil rolling for INDAL. This set a new benchmark on foil processing.

Key member of ALCAN task force for driving Process Improvements from the Cast house to sheet rolling and foil making.

Introduced new and effective methods for characterizing grain refiners and choosing the best for optimizing the process to reduce variations.

Streamlined R&D activity for defect characterization as a support function for 5 INDAL plants - The Belgaum R & D Centre became a nodal point for such activities.

Won the best SEM (Scanning Electron Microscope) metallography award organized by the Indian Institute of Metals, Calcutta in the year 1994

PROJECT ASSISSTANT From : 1985 to 1991

DEPARTMENT OF METALLURGY

INDIAN INSTITUTE OF SCIENCE, (IISC) BANGALORE.

Developing new alloys and testing materials for the Aerospace industry.

Aluminum – Lithium alloy for the Light Combact Aircraft (LCA) program was successfully developed

Published 3 technical papers in International Conference.

Academic and Professional Credentials

M.Tech. (Materials Engineering), 1993 from Regional Engineering College, (REC) Surathkal, Karnataka : Now NIET

Won the A.K. Bose Gold Medal for the best M.Tech Thesis in the country awarded by The Indian Institute of Metals, Calcutta in the year 1993.

AMIIM 1991 : Indian Institute of Metals, Calcutta

BSc : Physics, Chemistry & Mathematics 1985 from Sri Sathya Sai Institue of Higher learning, Puttaparthi, A.P.

Personal Details :

Date of birth : 1st October 1963

Residence : Chennai

Marital status : Single

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