A.MANI

H***, Sreevatsa Residency,

No :**, Mettupalayam Road. Mobile : 098********

G N Mills,Coimbatore - 641029 E-Mail : adkdpz@r.postjobfree.com

Tamil Nadu, India. adkdpz@r.postjobfree.com

PROFESSIONAL SYNOPSIS

A graduate mechanical engineer with 3 decades of experience in Manufacturing Operations and Product Development.

Currently working with M/s Roots Industries India Ltd, Manufacturer of Automotive Horns, automobile accessories and Furniture and Appliances, as Chief Operations Officer.

Extensive experience in planning of production functions involving resource estimation and man management.

Excellent knowledge on optimizing resources utilization and inventory reduction.

Experience in leading the team to implement Lean Manufacturing concepts in manufacturing processes.

Experience in implementing Toyota Production System in the TKML product’s production lines across the organization

Experience in implementing BIG M Flow concepts (VSME)

Excellent knowledge and working experience in new production line establishment, lean manufacturing concepts like Kanban, Gemba kaizen, production levelling, poka-yoke, Andon, 5S, JIT, 6 Sigma and Quality Management Systems ISO 9001, QS 9000, ISO/TS 16949, & ISO 14000

Well conversant with FIFO, Poke-Yoke, TPM, Kaizen & Line Balancing

Expertise in implementing FMEA, MSA, SPC Techniques, abnormality reporting, short interval control system, zero defect, standardized work, poka-yoke systems as continual improvements.

Proficiency in analyzing manufacturing processes, identifying areas for improvement and implementing corrective action for reducing / eliminating defects, rework and consumption of resource.

Experience in implementing cost saving measures to achieve substantial reduction in terms of cost of manufacturing as well as the product.

Core Team member for implementing SAP- PP Module

Experience in conducting PPAP runs and PPAP documents

An effective communicator with excellent interpersonal & relationship management skill

PROFESSIONAL EXPERIENCE HIGHLIGHTS

1. Name of the company : M/s Roots Industries India Ltd., Coimbatore

Designation : Chief Oparations Officer – Automotive Division and Furniture & Appliances Division

Duration : 13th June’18 to till date

Company Profile : Roots Industries India Limited (RIL) established in 1970 is the flagship company of the Roots Group and its products find pride of place in some of the world’s most respected automobile brands. The company manufactures a wide range of Electric Horns, backup alarm and electronic horns with multi-functional capabilities for passenger vehicles, off-road vehicles and material handling equipment.

Responsibilities :

P&L Responsibility.

Presenting annual budget to the apex committee and monitoring the budgeted cost.

Lead and manage the operation

Improving Inventory Turn Over

Reducing manufacturing overhead and Employee Cost

Plan strategies for enhancing production as well as productivity

Customer Schedule Adherence

Set targets for the measure of performance and guide to achieve the targets.

Ensure optimum utilization of resources.

Productionize new products within the lead time and ramp-up production.

Monitor productivity and ensuring corrective measures.

Drive continuous improvement

Improve the morale of employees

2. Name of the company : M/s Sharadha Terry Products Ltd.,- KG Worldwide, Coimbatore

Designation : Vice President Operations

Duration : 31st Jan’18 to 12th June’18

Company Profile : Sharadha Terry Products Ltd is one of the leading home textiles companies in the World exporting bath products to leading retailers across the world including USA, Canada, Japan, Australia, New Zealand and Europe.

Responsibilities :

Lead and manage the operation

Reducing manufacturing cost

Plan strategies for enhancing production as well as productivity

Customer Schedule Adherence

Reduce B Grage and C Grade Rejections.

Set targets for the measure of performance and guide to achieve the targets.

Capacity planning and enhance capacity wherever required

Ensure optimum utilization of resources.

Productionize new products within the lead time and ramp-up production.

Monitor productivity and ensuring corrective measures.

Drive continuous improvement

Improve the morale of employees

3.Name of the company : M/s Amalgamations Repco Ltd., Chennai

Designation : General Manager – Manufacturing

Duration : Jan’13 to Jan’18

Company Profile : Amalgamations Repco Ltd., Chennai, a Rs2000Mn turn over company, India's leading manufacturer of automotive clutches and ring gears. An ISO9001, ISO/TS16949 and ISO14000 certified company.

Responsibilities :

Lead and manage the operation

Plan strategies for improvement.

Customer Schedule Adherence

Reduce Customer end rejections..

Set targets for the measure of performance and guide to achieve the targets.

Capacity planning and enhance capacity wherever required

Ensure optimum utilization of resources.

Productionize new products within the lead time and ramp-up production.

Monitor productivity and ensuring corrective measures.

Implement manufacturing systems like TPM and Lean Manufacturing.

Drive continuous improvement

Improve the morale of employees

2. Name of the company : M/s Pricol Ltd., Coimbatore

Designation : Program Manager – Product Development & Engineering

Duration : July’10 to Dec’12

Company Profile : Pricol Ltd., erstwhile Premier Instruments & Controls Ltd., Coimbatore, a Rs.9400 Mn turn over company, India's leading manufacturer of automotive Instrument Clusters and Gauges, Sensors, Oil Pumps, Valves, Engine parts, Fleet Management Systems, Remote Keyless Entry and Immobilizer Systems. An ISO9001, QS9000, ISO/TS16949 and ISO14000 certified company practicing TQM, TPM, SCM, SAP R3, Wind-Chill and 6 sigma.

Responsibilities:

Offering the existing technology of Switches & Sensors products to the customers.

Ensuring cost competitive quote to the customer.

Coordinate with customers for technical discussions as well as for the product milestones

Design and Development of Switches & Sensors for most of the Indian 2 wheeler, 4 wheeler, commercial and off road vehicles OEMs and for international customers with a team of 20 engineers.

Review and ensuring the milestones of the project.

Productionizing the product, conducting PPAP run, product handing over sign-off with stake holders with handing over of PPAP documents.

Maintaining the records pertaining to ISO 9001 and ISO/TS 16949 systems.

Achieving annual turnover fixed by the management for the development of Switches & Sensors

Reviewing the customer and internal quality issues in the lifecycle of the product taking corrective actions.

Key Achievements:

54 new products productionized in the year 2011-12 contributed to a turnover of Rs.63 Mn from new products.

Designed and developed a NO type pressure switch, a different type from the existing design and offered to M/s Volvo, India contributes to Rs.5.0Mn turnover per year.

Developed a TFR type pressure sensor from a Chinese source to improve the reliability of the product form 30 thousand cycles to 10 lakhs cycle.

Rs.2.7 Mn savings given from material cost reduction through value engineering and new source development in the year 2011-12.

4.Name of the company : M/s Automotive Infotronics Pvt Ltd

Designation : Head – Costing, Vendor Development, Procurement, Quality, productionizing & production

Duration : Dec’09 to July’10

Company Profile : M/s Automotive Infotronics Pvt Lts is a company of 50:50 Joint Venture between Ashok Leyland and Continental, Germany, develops Instrument Clusters, Body Control Units, Current Sensors, Telematic Systems and Electronic control Units for Commercial Vehicles.

Responsibilities:

Develop and establish production lines at supplier premises.

Productionise the product and conduct PPAP runs at supplier end.

Ensure Quality, Cost & Delivery Schedule adherence in sourcing manufactured components from vendors & supplying it to the customer.

New supplier / source identification as a manufacturing partner.

Problem solving and analysis at supplier’s place for production & quality.

Ensuring delivery schedules are met for customer delight.

Key Achievements:

New source identified and production line developed for ECP for Ashok Leyland.

Production established for multiplexing system and 100% delivery schedule achieved

5. Name of the company : M/s Pricol Ltd., Coimbatore

Designation : Head –Strategic Operating Unit I (Manufacturing operation)

Duration : Nov’92 to Dec’09.

Key Responsibilities : Responsible for Receiving inspection, Stores, Product assembly, Product inspection and Packing & Delivery.

Responsibilities:

Lead and manage the SOU team for the manufacturing of mechanical and electronic instrument clusters for 2 wheeler, 4 wheeler, commercial and Off Road vehicle OEMs contributing to Rs1400 Mn Turn Over per year.

Develop Capacity and man power resource plan and approve. Interface with senior management for any constraint.

Develop production plan and production schedule.

Lead the team to ensure team deliverable like schedule adherence, productivity, first time acceptance, in-process rejection, WIP inventory, value addition per man day targets are met.

Set continuous improvement targets and identify projects & actions to achieve them.

Implement and establish SPC techniques and improve process capability.

Implement short interval control system.

Ensure effective utilization of Man, Machine and Material.

Implement TPM activities in all the production lines.

Establish new production lines for new product / existing products.

Effectively coordinating with enabling departments like Product Development Engineering Dept. Quality Engineering Dept., Materials Dept., Manufacturing Engg Dept., etc., to ensure smooth and hassles free productionising of the new products.

Lead and implement continuous improvement systems like Lean Manufacturing / Toyota Production system, TPM, kaizen, Poka Yoke, kanban, FIFO, single piece flow, etc.,

Identify and initiate sub-assy outsourcing to reduce the man power.

Train and develop the personnel by coaching and mentoring & ensure required skill levels are available.

Motivate the employees.

Man management and absenteeism control.

Generate and implement suggestions to meet the cost saving target.

Ensure the manufacturing processes are complied with Environment, Health and Safety.

Additional Responsibilities:

Lead ‘Toyota Production System’ implementation team in consultation with Toyota Kirloskar Motors Ltd

Lead ‘Lean Manufacturing System” implementation team & implemented with the coordination of M/s Festool Inc., Germany

Internal Auditor for ISO/TS 16949 and ISO 18000 systems.

Notable Key Achievements:

Established 2 new production modules ie) instrument cluster production lines for export customers like Suzuki, Thailand and Indonesia, Kawasaki Thailand, Phillipphine Auto components, Piaggio Italy, MBK France & Electronic Instrument Clusters lines contributing to Rs.500 Mn turn over

20% improvement in all the KPI parameters in 20 in 2001 project

150% productivity improvement in export instrument cluster assy line achieved over a period of 2 years by implementing kaizens and debottlenecking the process.

60% productivity improvement achieved in speedo system assy line by implementing kaizens and reducing rejections.

Fisher Die casting m/c output improved from 450 nos per hour to 600 nos per hour by implementing kaizens and rejection level reduced from 15% level to Nil by modifying the die design.

Inventory turn over improved from 7.5 turns to 11 turns over a period of 18 months.

WIP inventory reduced from 7 days inventory to 2 days inventory by implementing issue control system.

Achieved Zero ppm of export OEM instrument customer rejection with respect to manufacturing defect

Implemented value engineering/productivity improvement suggestions resulting in cost saving of Rs.7 Mn over 3 years.

15 operators reduced by outsourcing the sub assy manufacturing process to the component suppliers over a period of 12 months.

First Time Rejection reduced from 14000 ppm to 5700 ppm over a period of 2 years.

SPC charts implemented in 85 processes.

Implemented Single piece flow and FIFO in instrument cluster assy lines throughout the organization for the record first time in inspection.

Won “Best 5S practicing department” trophy for continuous 3 years.

6. Name of the company : M/s RAP Mfrs Ltd., Hosur.

Designation : Engineer – QA

Duration : Mar’91 to Oct’92

TRAINING & WORKSHOPS & CONFERENCES

‘Lean Manufacturing’ implementation in consultation with M/s Festool Inc., Germany.

One week intensive training on ‘World Class Manufacturing Techniques’ conducted by CII, New Delhi.

Two weeks training in ‘Statistical Quality Control Techniques’ conducted by ISI.

On the job training of ‘Process validation and productionisation’ by DENSO CORPORATION, Japan.

‘Toyota Production System’ training program conducted by M/s TKML, Bangalore

VSME graduated from JICA and CII India. Project done under the guidance of Dr Furugasi Takeyuki, a world renowned consutant.

TPM under TAFE Supplier Cluster By TPM Club India.

COMPUTER SKILLS

MS Word, Excel, Power Point, Auto Cad

SAP / ERP package

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