SHIVAKUMAR P

E-Mail:adjytd@r.postjobfree.com Mobile: +91-944*******/ +91-944*******

PROFESSIONAL PROFILE:

Auto motive components Manufacturing with 30 years + years of Experience in Automotive components manufacturing Tool Room & Tool Manufacturing cum Resharpening,with Quality Management along with Manufacturing engineering,Mainteance,purchase,Logistic,HR and implementing of Lean and Industry 4.0 Emerging Technologies.

Brief Over View:

Profit driven result oriented executive with 30 + years of experience in the Toolroom and Manfacturing of Toolingsand Manufacturingengineering of capital Goods,equipments.Drive Lean Manufacturig,Kanban,andContinuous improvement initiatives to build high quality, cost effective operations in Automotive industry seekinga senior management position to achieve the goals and objective of the company.

Strength:

1.Effective and accountable

2. Consistentlydelivers results

3. Strong knowledge in operations,

4. Respect and leverage human capital person

Professional Overview:-

Graduate Engineer B.E(Mechanical) – VMRF – 2008 with 30 years significant Experience

Diploma in Tool Makingfrom Central Institute if Tool Design Hyderabad–– 1988

Outstanding achievements in key leadership and management positions. Self-starter and team motivator, using leadership and vision to turnaround failing operations. Ability to handle demanding assignments concurrently

Professional Job Summary:-

NAME OF THE EMPLOYER

DESIGNATION

FROM

TO

Greaves Cotton LimitedRanipet and Auranagbad– Maharashtra

Senior Manager Manufacturing Engineering

Sep 14

Present

Ashok Leyland Limited,Hosur

Manager Production Engineering and Projects

Oct10

Sep14

Hyundai Motor India Ltd,Chennai

Dy. ManagerToolings Head ETM

Dec 06

Oct10

Rane Engine Valves Limited, chennai

Senior engineer ManufacturingEngg.

Sep 02

Dec 06

Lucas TVS Limited Chennai, Chennai

Module Leader Production

Sep99

Sep 02

L&T Komatsu Limited

Bangalore

Assistant Engineer Toolroom&Support Services

July95

Sep99

Ashok Leyland Limited,

–Bhandara Maharashtra

Production Engineer – Toolroom&Planning

July88

July95

Major Highlites in my career:-

Heading the Automotive components Manfacturing&Toolroom with RequalificationToolings,Practical knowledge ofManufacturig of Presstools, like Piercing,Punching,LaminationDies,Hot Bending Tools ECR cutting,Tools.Design and Manufaturing of JIgs and Fixtures,VMC Fixtures & Injection moulds.etc

Exposure to Design and making of Injection mouds and New Components prove outs with machine like 50Ton Windsor injection moulding machine.

Exposure to Deckel Die sinking,SIP double column Jig Boring Machines EDM,WireCut Machines.

Manufacturing Process Design of Engine 4c Components like Crank case. Cylinder Head, Camshaft, Connecting Rod for Automotive and Farm equipment Engines. And also Engine Assembly and Testing

Process Development of ZF Gear Box Assembly and Machining of Gears & Shafts Hard and soft Stage,HT.

Development of Engine Valve Spiral Polishing Machine.

Low Cost automation of BSIV Engine Oil and Fuel Gallery Leak Testing Machine, Gear Roll Test Fixture, Engine Valve component Loading and Unloading

Auxiliary Gear Box Projects for Defense Application including Assembly Machining of Gears and Shafts.

Pre engaged starter Motor Armature line Process Layout changed to cellular manufacturing Product layout, U shaped cell forming. Kangaroo cell, Forward Reverses’ assembly.

IntroductionKanban System, TPM Model line, Single piece flow,Chaku – Chaku”introduction, PDCA for DWM, GapAnalaysis,Lean and JIT implementation

Implementaion of Lean Projests and Hightite of the projectsasmentione below :-

LEAN PROJECTS :

S.#

Project Title

Lean Tools/

Concepts applied

Role

Role Outcome of the project

1

Lean System Approach to G 435 Engine Assembly based on Rebalancing,Relocating of Testing stage,,removing Bottle neck operation, Automation

Company: Greaves

Cotton Ltd, Ranipet,

India. Leader in

manufacturing of Diesel/Petrol Engines, Gen sets and Pump sets.

Chaku-Chaku, Single

Minute Exchange of

Die (SMED), value

stream mapping

(VSM), Jidoka, 5S,

Multi machine

handling, Multi

process handling,

SOP, Visual management, One

piece flow, Cellular

layout, and Total

productive

maintenance

Lean project

leader for

executing the

project with an

internal cross functional

team.

Number of Stages made reduced from 29 to 26 stages.

No of Operator reduced from 58 to 52 nos.

WIP reduced from 787 nos to 745 Nos.

Movement Distance reduced from 647 to 430 Meters.

Total Lead time reduced from 866 Minutes to 812 Minutes

2.

Consolidate two

Engine Valve Inlet with Exhaust Line for Hyundai valve to one Inlet,Exhaust line,Elimination Turn seat and intermediate Cless,Auto loading and unloading

Company: Rane engine Valves Alandur Chennai

India. Leader in

manufacturing of Engine valve and Valve guides

.

5S, Visual

management

stream mapping

(VSM),Five Whys,

, Kanban,Jidoka

system, value

Cellularlayout,

My role was to

execute lean tools

and concepts and

drive business

results directly. Itis both "do it "and influencer type of

role.

Productivity per operator from 222 nos per shift to 500 nos per shift

No of Operator reduced from 9 to 4 nos.

Cell Layout changed from Straight line to U shape layout.

Manual loading changed to Auto loading and Unloading.

3

Reform layout into

“see-through” arrangement

to improve

Space, Productivity

Company: Ashok Leyland Limited Hosur

India. Leader in

manufacturing of Commercial vehicle

Chaku-Chaku,

Value stream mapping

(VSM), Jidoka, 5S,

Multi machine

handling, Multi

process handling,

SOP, Visual management, One

piece flow, Cellular

layout

Lean project

leader for

executing the

project with an

internal cross functional

team

Reduce cycle times of both machining

& assembly to meet customer demand

( Cycle time < TAKT Time of 130 sec )

Reduce inventory from 3.83 days to less

than 1 day

Improve uptime of machining cell to greater

than 85%

No of Operator reduced from 3 to 5 nos.

4

Consolidate two crankcase manufacturing cells into one cell by arranging the machines based on process flow with an increased output

Company: Greaves

Cotton Ltd, Ranipet,

India. Leader in

manufacturing of Diesel

/ Petrol Engines,

Gen sets and Pump sets.

5S, Visual

management

system, value

stream mapping

(VSM),Five Whys,

, Kanban,JidokaCellularlayout,

My role was to

execute lean tools

and concepts and

drive business

results directly. Itis both "do it "and influencer type of

role.

Output/machine increased from 25 to 40 nos.

Reduction in number of operators from 40 to 24

Maintained see-through line at all times

Number of machine used in the line reduced from 25 to 20 machines

5

Introduction of Forward and Reverse assembly, Single piece flow.

Chaku-Chaku,

Value stream mapping

(VSM), Jidoka, 5S,

Multi machine

handling, Multi

process handling,

SOP, Visual management, One

piece flow, Cellular

layout

My role was to

execute lean tools

and concepts and

drive business

results directly. Itis both "do it "and influencer type of

role.

Number of Stages made reduced from 28 to 26 stages.

No of Operator reduced from 28 to 26 nos.

WIP reduced from 287 nos to 245 Nos.

Movement Distance reduced from 347 to 330 Meters.

Work Summary :-

New Process Development,ToolRoom and Design In–charge of Single Cylinder 4C Components like Crank shaft, CrankCase, Cam shaft, Con Rod,Outputshaft, Input Shafts,Lay Shaft, High-speed Gear, Rear axle, Front Axle Assembly, Defense Gear box machining components. Exposure to Engine Assembly and Testing of Single Cylinder components

In charge for Capex planning,Selection New machine tools, ordering, Erection and commissioning Conducting cutting trials, Pp, Ppk study and productionising.

Spearheading Manufacturing Engineering, Toollings, Fixture design, Gauges and Project development functions of Capacity planning and Productivity improvements

Program In charge for New product introduction Light Agro Engine and GensetsComponents development and in-house and Vendor source Development.

CFT Head for Lean Implementation projects

Capacity planning and cell re-engineering of machining and assembly process

The track record for meeting timelines and exceeding expectations.

Experienced in PPAP/APQP quality processes

CFT Head for Cost Saving projects

Developed highly accurate production floor plan spreadsheet to track production inventory by tool and process for each shift for initial Production.

Exposure to Design of Injection Moulds.Press Tools, Jigs and Fixture like Welding Fixture, Grinding Fixture, Turning Fixture, HMC Fixture, Drill Jigs, Gauges and Tooling’s, Press tools like piercing blanking drawing combination tools using 500 Ton Hydraulic Press, mechanical presses .

New product development and new process support

Preparation and updating of APQP and PPAP documents like FMEA,PFD

Improve Productivity through multi machine manning & combining of operations

Line balancing,cycle time reduction, Effort reduction and Line handling material handling systems.

Lean six sigma Green belt member for structured problem solving methods.

Statistical Process control for Critical Dimensions and Troubleshooting to achieve Cpk 1.67 by eliminating causes

Development of new facilities for Productionising new products PPAP run

Programming and working knowledge in CNC lathe, LMW, FEMCO, ACE,KWS Lathe, STC 25, HTC 600 etc., using both Sinumeric, Fanuc. Languages, Special purpose hydro-pneumatic machinery, Mechanical Forging Presses including Up Setter, Centre less Grinding machines, Plasma Transfer Arc Machine, and Special Purpose precision grinding machines Walter 5 axis CNC Tool and cutter Grinder Gleason Gear cutter Grinder. Kliengenburg Hob Re Sharpening .Machine .Pentagon Broach Re Sharpening Machine, Dormer Drill Grinder, Hurth Shaving Cutter Grinder

Well experienced in Facility Planning, Equipment planning, selection and installation &productionisation process by a systematic approach

Proficient in establishing new machining and assembly cells, Process planning, new product development, Line balancing, Lean manufacturing standards

Handling of Capital budget planning and monitoring

Better team player in new initiative's implementation such as SAP, TS 16949 & TPM

Team leader of the Total Productive Maintenance.

Task force Team member of the “Achieve 100 PPM project.

Developed Forging drawings from 3D Models for all new components (Camshaft axle arm,droparm,crankshaft,OutputShaft, Input shaft, Lay shaft, and corresponding Gears.

Developed Project Gantt charts, PFMEA, Process sheet for machining and Assembly, Stage Drawing’s, Control Plans etc

Selection of machines and related Tooling like Hobs, Shaper cutter, Broaches, and Gear grinding and OD grinding wheels

Design and Manufacturing ofPressTools,Moulds,Jigs& Fixtures and Handling equipment required for machining and Assembly and Toolings.

Ordering and souring follow-up with suppliers to meet Project timelines.

Conducting Cp,Cpk trials, SOPP & regular Production.

Significant Achievements Made in Manufacturing Engineering So Far:

Highlights:

Concept Design and Development of Spiral polishing M/c.Was successfully developed for Engine valves. De Skilling of Manpower, Manpower per shift savings has been achieved

Concept Design and Development of BSIV Engine Oil and Fuel Gallery Leak Testing Machine made with unused items.,,

Spring Brake Actuator forks process changed from forging to Fabrication route (Pressing and welding) by which component manufacturing cost reduced from Rs 27.20 to Rs 18 per components

Slack adjuster bearing retainer process changed from Bar machining to cold forging route by which component manufacturing cost reduced from Rs 21 to Rs 17.20 per components

New Drift developed for internal Cir clip pressing in Gear box assembly.

Pilot bushing introduced for bearing inserting and removal in the Stallion Rear Axle Assembly.

Poke yoke made for Track arm small boss milling to avoid wrong loading and operation scrap.

SNMA 120408 H1P (INSERT) was used for Facing Operation & TNMA 160408 (INSERT) was used for Head DIAturning. After improvement the unused cutting edge of SNMAinsertwas used for Head Diaturning, thus eliminating TNMA insert. Around 2 Lacks per annum is saving was achieved

Cost reduction is made by increase the number of cutting in face milling cutter from three to Eight cutting edge by which 1 lacks per annum is cost saving

Cost reduction is made by increase the number of cutting edges. For example VNMG 130404 was introduced in place of VCMT 160404 insert by whichRs. 2 lacks per annum saved.

Cycle Time reduction up to 30 percent achieved by modifying the fixture from single components to double component machining at a time (Gear Hobbing, High and Low speed Mark4 Gears & Track arm).

Cycle Time reduced from 10 to 5 mins through the introduction of Multi Spindle Head attachment for Track arm (Drill Four holes in a single cycle).

Low cost Automation of BSIV Engine Oil and Fuel Gallery Leak Testing Machine, Gear Roll Test Fixture Gear Roll Testing Fixture made in house for Manpower reduction to reduce Gear meshing noise reduction

LCA made for Engine Component loading and unloading arrangements

600 series Crank shaft Line High speed line Formation with 90 sec Takht Time by Rebalancing existing lines.

Cost reduction is made by increase the number of cutting edges. For example VNMG 130404 was introduced in place of ofVCMT 160404 by which Rs. 2 lacks per annum saved.

Increased Production in Hero Honda Valve line to 10,000 to 11,500 per day by forming separate Cell type lines for Inlet and Exhaust Valves through changing process layout to product layout

Introducing a combination cutting tools for cycle time reduction in Valves

One of my interesting Costs saving Project is AL TIN Coating to our existing carbide insert/drills tool Life has been increased to 60 % annual savings to the Company is 16 Lacks per annum

New method (Water immersed brazing) is introduced to solve Size variation problem after Brazing and welding in Clutch booster air Cylinder.

Spring Brake Actuator forks process changed from forging to Fabrication route (Pressing and welding) by which component manufacturing cost reduced from Rs 27.20 to Rs 18 per components

Slack adjuster bearing retainer process changed from bar machining to cold forging route by which component manufacturing cost reduced from Rs 21 to Rs 17.20 per components.

Process Improvements in output rear Gear Unwash Problem by Modified Fixture Design.

Cost reduction is made by increase No flutes from 4 Reamer flutes to 6 flutes in connecting rod which Reamer life increased from 250 nos.to 50 nos Savings 10 lacks/annum.

Chaku – Chaku” is introduced in Commentator Diamond Turning.

M8X1.5 Tap life increased 50% by changing the Tap material from M2 to M35with 10 % cobalt.

Crankshaft pin grinding wheel Material changed from aluminum oxide wheel to Seeded Gelgrinding wheel by which cost per car is reduced from Rs 9.52 to RS 4.50 Annual Saving is 14.2 lacks.

Single piece flow of different type of cells like variant cells and Nagare Cell concept

Achieved the cost reduction of Rs50 Lacks in Overhead crane installation standardization.

Cost reduction of cutting tools by increasing the life .purpose grinding wheels by using the unused grinding with PLC modification in the machine

Manual application of flux results in improper application of flux which affects Soldering flow. A semi auto SPM with armature rotation & auto flux dispensing is made.

Elimination of non –value added activities,

New method (Water immersed brazing) is introduced to solve Size variation problem after Brazing and welding in Clutch booster air Cylinder.

Increased Production in Hero Honda Valve line to 10,000 to 11,500 per day by forming separate Cell type lines for Inlet and Exhaust Valves through changing process layout to product layout

Introducing a combination cutting tool for cycle time reduction in Valves

One of my interesting Costs saving Project is AL TIN Coating to our existing carbide insert/drills tool Life has been increased to 60 % annual savings to the Company is 16 Lacks per annum

.Team Size: Managing and Leading a Team of one Asst Managers, Six Engineers, and Three Junior Engineers and 70 operators

Skill sets:-

AutoCAD 2011, / A-Desk INVENTOR

SAP-PP module & SAP-MM user module

MS-Office (MS Excel, MS Word & MS PowerPoint)

Product Life Cycle Management (PLM)

PROFESSIONALLY TRAINED IN:-

Lean six sigma Training given by Black belt Champions

Modern Metal Cutting Application Engineering Course by Sandvik Pune

IATF 16949, FMEA, MSA, DOE core tools Training.

Current Salary : Negotiable

Expected Salary : Negotiable

Languages Known:

Read Write Speak

Tamil Yes YesYes

English Yes YesYes

Hindi Yes

Telugu Yes

Kanada Yes

PERSONAL ViTAE

1. Name : Shiva Kumar P

2. Father’s Name : Perumal T.M

3. Permanent Address : 15 A Venkatarishana Street V MarudhurVillupuram

4. Date of Birth : 07.05.1964

Yours Faithfully

(SHIVAKUMAR P )

Place: Chennai

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