Manager Engineer
Resume:
RESUME
KARUPPAN.V
Gokulam Lakshmi Apartments
Sundar nagar
Poonamalle
Chennai-56
Mobile: 080********
E-mail: ********.*.***@*****.***
Vision:
To be a target oriented professional in the field of Autombile Industry and will prove to be a continuous Leader and Learner.
PROFESSIONAL SUMMARY:
Around 15+ year’s professional experience in the field of Automobile, Manufacturing, project management, new product introduction, Process & Equipment Planning etc. Hands on experience in Greenfield and Brownfield projects
Company Name
Period
Designation
Daimler India Commercial Vehicles Limited Chennai,Tamilnadu
From May 2010 to till date
Senior Manager –Manufacturing Engineering
(Powertrain –Transmission assembly and testing)
Tata Motors Ltd, Pune
From March‘ 07 to May 2010
Manager – Manufacturing planning ( Nano Project)
TVS Sundaram fasteners Limited ( Autolec division )
Chennai
From Feb 06 to Mar ‘07
Engineer – Production (Assembly shop)
Neel Industries Limited ( JBM group)
From Oct 04 to
Feb 06
Engineer – Production (Press shop)
PRESENT EMPLOYER
Daimler India Commercial Vehicles Limited – Chennai
Period : May 2010 to Till Date
Designation : Senior Manager (PowertrainshopPlanning –Transmission assy and Testing).
Responsibility : Process & Equipment Planning, Implementation of Greenfield projects
Projects Handled
i)From 2010 to 2012 – as Manager - Plan, execute and prove assembly line for Medium duty truck transmission (Greenfield project)
ii)From 2013 to 2014 – as Manger - Lead for Assembly line integration (combine medium duty and heavy duty transmission line into single assembly line – (Brown field project)
iii)From 2014 to till date –as Senior manager - Lead for Planning and prove out assembly and test bench facilities for Export Medium duty truck transmission (Green field project)
Roles and Responsibilities:
Project lead for Transmission assembly and Testing
Provide budget estimate for all new transmission projects to the management
Provide multiple layout scenarios for management approvals
Submit Manufacturing engineering status to projects for each quality gate approvals
Process planning for 5 mins takt time and do bench mark study with mother plant at Germany, Japan and Brazil.
Prepare of RFQ as per product requirements and do detailed technical discussion with suppliers for the planning of equipments like End of line Test bed, Assembly Press, Nut runners, Washing Machine,Leak Test machine etc.
Ensure all the suppliers are inline with the technical specifications and give recommendations to purchase team for ordering process
Approve the Design of the equipment (DAP) as per Technical specification
Coordinate with suppliers and ensure the equipment readiness for equipment preacceptance at supplier end
Responsible for Installation and commissioning of equipments like end of line Test bed, conveyors, Assembly Presses, Assembly line equipments as per planned takt time.
Complete line prove out in three stages tryout 1, tryout 2 and tryout 3 and ensure the line readiness for SOP
Ensure all the quality parameters meet as per the technical specification during prove out stage
Ramp up the assembly line as per the planned capacity and handover to production, quality and maintenance
Capitalize the planned equipment by meeting Financial requirements
Design review and process review, Engineering change proposals with respect to Quality, Safety & cycle time.
Prepare, Evaluate & Finalize the Layout for Manufacturing Process as per Takt time
Analyze station wise Safety & Ergonomics for the production line and implementing corrective action.
Prepare process related documents like PFD, PFMEA, Control plan, Audit documents for Process & Product etc.
Analyze the Maintenance accessibility & TPM related improvements in the equipments during DAP stage & implementing corrective action in the equipment.
Identify and implement Low cost automation
QMS representative for Manufacturing Engineering,Implementation of IATF,ISO 140001,ISO 450001,ISO 500001
PREVIOUS EMPLOYER – Third
TATA MOTORS LTD – [Sanand Plant, Ahmedabad – Nano Project].
Period : March 2007 to May 2010
Designation : Manager (Power train shop Planning).
Responsibility : Process & Equipment Planning, TATA NANO (1 Lakh Car)
Projects Handled:
I.From 2007 to 2010 - Plan, execute and prove Transaxle assembly and testing facilities
(Green field projects)
KEY RESPONSIBILITIES
Working as a Small Car Manufacturing Planning Engineer and responsible for,
Process planning for 52 sec takt time line of Power train Assembly for Small Car TATA NANO (1 Lac Car).
Preparation of RFQ and detailed discussion with suppliers for various equipments including End of line Test bed, Assembly Press,Multispindle Nut runners, Washing Machine,Leak Test machine etc.
Analyze the equipment specifications and functionalities, sending the technical comparisons and recommendations for further commercial negotiations by purchase representatives.
Approving the Design of the equipment (DAP) as Technical specification
Successfully Installed & commissioned equipments like end of line Test bed, conveyors, washing machine, Assembly Presses, Assembly line as per takt time.
Design review and process review, Engineering change proposals with respect to Quality, Safety & cycle time.
Preparing Work content for individual operators & Cycle time for individual Process using MOST Techniques & Line balancing as per Takt time
Preparation, Evaluation & Finalization of Layout for Manufacturing Process as per Takt time
Analyzing station wise Safety & Ergonomics for the production line using Rula Analysis and implementing corrective action.
Preparing process related documents like PFD, PFMEA, Control plan, Audit documents for Process & Product etc.
Analyze the Maintenance accessibility & TPM related improvements in the equipments during DAP stage & implementing corrective action in the equipment.
Preparing JH schedule, PM schedule for all planned equipments.
Tryout of complete line in singur plant
Tryout of complete line of 90K project in pune.
Successfully installed and Commissioned, Process proved at Singur,Pune and at Sanand
Successfully made PO, PP batches & ramped production upto 300 per day at Pune Powertrain Production facilities.
Reduced 15 manpower using Low cost Automation.
Implemented the TPM procedures for Power train line equipments like preparation of MFMEA, JH schedules, PM schedules, etc.
As Team leader for 5 Kaizen events (3P - Production Preparation Process as called in Tata Motors) along with Cross functional experts for achieving desired scope in TPM, LCA, and Ergonomics etc.
63 Pokayoka Identified through Pokayoka exercise & Implemented in planning stage
854 Improvements identified through TPM activities & Implemented in the equipment
25 LCA identified & Implemented in the Production line
PREVIOUS EMPLOYER – Second
TVS Sundaram Fasteners Limited – Autolec division
Engineer – Production (Assembly shop)
Nature of work:
Preparing weekly Plan, loading plan and achieving schedule Vs adherence
Preparing SOP for all assembly processes
Preparing Monthly performance report
Deciding the Process Sequence as per the cell Layout
Co-coordinating activities with QC/Maintenance/Tool room/PPC/Development/Purchase
Submitting the Samples to the Customer and Getting Approval for the Same
Working as an Team Member in Preparation of Production Part Approval Process (PPAP)
Implementing Fail safe (poke- yoke) to meet the zero rejection
Major contribution in Productivity improvement
Handling fixtures equipments
Knowledge in Production part approval process (PPAP), Statistical Process Control (SPC) and Measurement Systems Analysis (MSA), FMEA.
TPM –Activities:
Preparing Optimal Condition Check sheet for Presses...
Preparing weekly rejection trend and taking corrective action.
Conducting Awareness Program for Operators.
Calculating OEE /OPE for critical Presses.
Conducting 5S Audit in each cell.
50 Fail-safe implemented. Some of us below:
Fail safe for ensuring oil hole opening for lubrication oil flow.
Fail safe for socket retainer assy for lubrication oil flow
Fail safe for interchanging position for intake valve and exhaust valve in assy.
Fail safe for socket groove width identification
Fail safe for roller height identification.
Fail safe for oil hole opening
PREVIOUS EMPLOYER - First
NEEL Industries Limited (JBM group) – Chennai
Engineer – Production (Press shop)
Nature of Job :
Exposure in sheet metal Pressed components & welded components
Customer complaints are addressed
5s activities –Zonal leader
Follow up activities with QC/PPC/TOOL / Maintenance/ Development
Daily Production plan and monthly performance report
Training attended on Gemba Kaizen, 5S Techniques, 3M, My Machine concepts
Trainings attended:
MOST – Maynard Operation Sequence Technique (work measurement tool).
PFMEA & MFMEA – Process & machinery failure mode Effects Analysis
MSA, Poka-yoke, Gemba Kaizen, LCA, Ergonomics.
EDUCATION
Bachelor of Engineering (MECHANICAL Engg)
P.E.T Engineering College, Vallioor, Tirunelveli
Manonmaniam Sundaranar University, Passed out in 2004 with 78.89 %( First with Distinction)
H.S.C
ST Mary’s Higher Secondary School, Vickramasingapuram
Passed out in 2000 with 87.5%
S.S.L.C
ST Mary’s Higher Secondary School, Vickramasingapuram
Passed out in 1998 with 92%
Curriculum Achievement:
Project Work: Conceptual design of I .C Engine using hydrogen as fuel
This project was telecast on Sun T.V Programmed Vannakkam Tamizagam (Namma ooru wingani) along with interview on 16.07.04.
The same was published on Daily thanthi (Ilaingar malar-sathaniyalar santhippu) with my interview on 28.05.05
The same was appreciated and awarded at National level Technical symposium
Computer Skills:
Hands on experience in AutoCAD, Microsoft word, PowerPoint, SAP- PS module, Team centre PLM, MDAT (MOST software) & DELMIA.
PERSONAL INFORMATION:
Date of birth & Age - 24 Feb 1982, 34 years.
Marital status - Married.
Nationality - Indian
Native - Tamilnadu
Languages known - English, Tamil and Hindi
Passport details: - G7871801, D.O.E – Mar 2018
Permanent Address - 8/155, Pillaiyar kovil st,
Sivanthipuram(kaspa)-627425
Tirunelveli (D.T), Tamilnadu
Willing to relocate - yes
I assure you that the above mentioned information’s are correct from the best of my knowledge.
Thanking you,
Yours Truly,
Karuppan.v
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