S. KUMAR Mobile: 098********~ E-Mail: adke3k@r.postjobfree.com

74B, Veeramamunivar Street, Vishalakshi Nagar, Santhosapuram, Chennai – 600 073.

Seeking senior level assignments in Plant Operations, Lean Production System, TQM and Supplier Quality Assurance with an organization of high repute in the Engineering / Automobile Industries.

Professional Abridgement

28 years of experience in Automotive / Engineering industries in Plant Operations, Lean Production, TQM, TPM, Continuous Improvement, Manufacturing, SQA, Process Enhancement and Man management.

Managing plant operations focusing on Safety, Health, Environment, Quality, Cost, Delivery and Moral. Managing OEM customers Maruti, Hyundai, Honda, Toyota, Daimler, Skoda, Tata Motors and Mahindra & Mahindra.

Currently working with M/s ATC Tires Pvt Ltd., (Yokohama off Highway Tires) as Manufacturing Head.

Proficient in managing & leading teams for running successful process operations & experience of developing procedures, service standards for operational excellence.

Proven abilities to enhance production process operations; optimise resource & capacity utilization; escalate productivity & operational efficiencies; while curtailing costs & expenses.

Proficient in managing technically advanced cost-efficient, state of the art production systems and processes.

Excellent analytical, troubleshooting, inter-personal and presentation skills with proven ability in driving numerous quality enhancement and process improvement initiatives across the career.

AREAS OF EXPERTISE

Ensure that manufacturing strategies and processes are in place to meet business objectives and operational needs in terms of price, quality and delivery targets and which enables the company to function and compete effectively in the market

Coordinate team activities to optimize cost performance of the plant through capital investment programs, optimizing operating working capital usage and minimizing waste through the development of a continuous improvement culture encompassing lean principles and clear strategic development

Monitoring overall functioning of processes, identifying improvement areas and implementing adequate measures to maximize customer satisfaction level.

Developing Suppliers by conducting gap analysis, identifying counter measures and support for implementation. Continuous training and auditing of process.

Planning & implementing the preventive and predictive maintenance schedules for improving the overall reliability & safety of the plant, personal and production process.

Monitoring processes & identifying deviations towards ensuring that the same will consistently manufacture products meeting pre-determined specifications and quality.

Support, comply and ensure complicity with Health & Safety regulations, the Company Handbook, Code of Conduct, Quality and Environmental standards, and all other Company policies and procedures

Provide leadership, coordination and coaching to the team, ensuring they are trained enabling them to achieve the operational and financial metrics within their areas of responsibility and succeed in their roles

Conducting negotiations with Labor unions towards resolving issues / grievances, signing agreements and maintaining amicable employee relations; overseeing the performance of subordinates, mentoring / motivating to improve their contribution

Provide leadership to departments under control and coach, mentor and develop direct reports and manage a high performing team that delivers continuous improvement, added value and cost reductions

CAREER SCAN

Mar’20 to till date M/s ATC Tires Private Limited, (A Group company of YOKOHAMA) Tirunelveli

General Manager - Manufacturing

Key Deliverables;

Responsible to set the objective and KPI's to all direct reportees in line with the company and plant objectives

Ensure KPI's are met – Safety, Quality, Productivity, Cost as per Annual, Monthly and Daily targets

Responsible for Maintaining and improving OEE, manufacturing process and Productivity improvements

Responsible for Systems and process control and management

Review the Consumption & Inventory status of Indirect Material on weekly basis with respect to approved budget

Maintaining harmonious Trust based Industrial Relations with employees and workmen and managing the employees of all the departments for the smooth production run.

Proactively build a culture of Safety with zero accidents, along with Plant Control department and other relevant stakeholders

Leading CFTs to improve Manpower Productivity (MHPT), Manufacturing Execution System (MES) implementation and Material movement optimization projects

Management Committee Members for TQM implementation and JH Pillar Champion

Highlights;

Successfully completed LTS with Union with Productivity increase and new working norms.

Implemented “World Class FID” by improving Ergonomics, providing inspection infrastructure and improved the FTR from 76% to 88%.

Reduced 12% indirect manpower through low cost automation, Time study and method improvements

Aug’17 to March20, M/s Asahi India Glass Ltd., Chennai

Plant Head (Responsible for Plant P & L)

Key Deliverables;

To monitor & implement SOP's for safety so as to build safe working environment by ensuring adherence to safety norms. Continuously improve EMS and OHSAS adherence.

Responsible to implement process excellence, to upgrade the shop floor, reduce process lead time, reduce cycle time and cost optimization.

Identify and implement projects to improve safety, quality, cost and delivery through DRM, Quality Circle, Kaizen and Six Sigma projects

Achieve & maintain the health of assets by continuous implementation & review of maintenance plan.

Achieve Customer’s targets in Field Quality, Receipt quality and meeting their standards.

Develop new models, Feasibility review & ensuring the development time line as per Customer development plan.

To identify technology gap v/s competitor & global bench mark. Study complete know how & regular update on the best technology available as well as technological changes.

To build up and maintain high morale and motivation, ensure resolution of plant members concerns

Interaction with Customer services to have an update on: Customer concern, improvement plans/action and any other new development

Highlights;

Managed worker’s strike efficiently and addressing perennial IR issues and created conducive work atmosphere.

Enhanced TEI scheme: Suggestion, Kaizen, Quality Circle, PDCA Projects and Jishu Hozen activities.

Achieved Q1 Award from M/s Ford Motors, Best Collaborative Vendor Award and Best Supplier Synergy Cluster Award from M/s Hyundai Motors and Best Supplier, Best Environment Managed company award from M/s Toyota

Reduced Supplier PPM from 760 to 150 PPM by continuous training, auditing and periodic review with their top management.

Improved Quality Management System in the plant resulted in reduction of customer PPM from 23 to 7.

Improved plant Profitability from 15.6% to 19.5% by reducing operational losses and contain personal and overhead costs.

Developed Green Field expansion for M/s KIA Motors and successfully started the mass production

July’2015 – July’2017, M/s Bridgestone India Automotive Products Pvt Ltd, Chennai

General Manager (Operations) – Plant Head (Responsible Plant P & L)

Key Deliverables;

Enhance safety of the plant by improving 3S, Practicing safety Rules, Finding hazards beforehand and conducting Risk Assessment.

Implement Fire Disaster Prevention by conducting continuous education and implement MUST 9 activities

Achieve customer PPM<5 and eliminate customer claims and complaints. Improve supplier incoming quality.

Improve productivity through workflow improvement, multi-skilling and implementing Single Piece Flow.

Reducing manufacturing scrap rate by introducing Quality Circle, Suggestion Scheme and Rubber Yield improvement.

Smooth launching of New Products for Toyota’s 640A, Isuzu’s RT64 & VD00 and Daimler’s localization parts.

Highlights;

Resolved perennial labor issues and improved their participation in TEE and Productivity Improvement Projects

Reduced manufacturing cost by 14 million INR per annum in the areas of power, consumables and transportation.

Implemented Cellular manufacturing using LPS and improved the productivity by 40% in assembly process

Reduced the manufacturing scrap rate by 0.8% within a year through successful implementation of projects

Achieved the ZERO PPM in Toyota parts for the year 2015~16 and achieved top 5 supplier in 2017-18. Reduced the export parts PPM below 5 PPM.

Dec’2000 – June 2015, M/s Rane (Madras) Limited, Chennai

Dy. General Manager (Operations) – Responsible for Plant P & L

Key Deliverables;

Maintaining profitability of the plant by adhering to the various Management Policies and devising strategies to enhance functionality.

Optimizing the inventory levels across the supply chain and integration of production activities with other departments by ensuring proper information flow.

Achieving plant targets as per the Annual Operating Plan; strengthening CFT force approach to adopt problem solving techniques to complete projects on time.

Controlling the Customer line complaints within 50 PPM for more than 20 customers with 390 products.

Working with Marketing and Engineering team to establish various product launch.

Ensuring adherence to all the control parameters in the plant to meet the statutory requirements.

Driving various Manufacturing & Logistic standards to implement Lean, TPM and Cost driving Initiatives to reduce variable and fixed cost.

Leading Strategy formulation and implementation team to increase SOB in Linkage products across customers.

Enhance Total Employee Involvement by improving their participation level in Suggestion, Quality Circle and Quality Improvement team. Facilitate to do benchmarking the best practice across industry.

Trainer for 7 QC Tools, 7 M Tools, DOE, Statistical Process Control, Kaizen and Lean Production System

Highlights;

Steering committee member to implement TQM Procedures and Practices. Won Deming Application Prize in 2007 and Deming Grand Prize in 2012.

Implemented LPS in 58 cells and reduce the cells to 23. Doubled the productivity, reduced the lead time by 50% and reduced the input resources by 70% in 3 years’ time.

SFG inventory reduced from 9 days to 3 days and RM inventory reduced from 28 days to 13 days.

Improved the machine availability to 98.6% by implementing and improving TPM procedures and practices

Developed ~50 New Products on an average for the last 4 years for various customers

Successfully led the team to negotiate with the union for LTS and achieve 20% productivity increase and soft issues to affect flexibility in Production and maintain discipline.

Best Manufacturing Practices Award from M/s CII & First Prize in TPM implementation from M/s ABK-AOTS.

Best Supplier Awards from M/s. Tata Motors, M/s. Mahindra & Mahindra and M/s. Mahindra Navistar.

Won the Safety Award from Government of Tamilnadu for implementing and practicing the best safety practices.

Co-ordinate with Prof. Washio and Prof. Ando for TQM implementation, Prof. Yoshida for LPS implementation

PREVIOUS ASSIGNMENTS

Tenure Organization Function

Jul’98 to Nov’00 IM Gears Pvt Ltd., Chennai Quality Assurance & NPD

Nov’94 to Jun’98 UT Ltd., Hosur Quality Control

July’92 to Nov’94 Sangam Aluminium Ltd., Hosur Production Supervisor

EDUCATION

Executive MBA - Indian Institute of Management, Kozhikode. - 2015

Post Graduate Diploma in Operations Management - Symbiosis, Pune in 2010

Graduation in Industrial Engineering - Indian Institute of Industrial Engineering, Mumbai in 2009

Post Diploma in Quality Assurance Management - Indian Institution for Quality Assurance

Diploma in Mechanical Engineering - Ramakrishna Mission Technical Institute, Chennai, 1992

Certifications;

Engineering Manpower Development Program (EMDP) conducted by Rane Institute for Employee Development

Certificate Course in Manufacturing Engineering Excellence (MEX) Organized by RANE Group and PSG Tech, Coimbatore in 2005.

Metal Cutting Application Engineering – Kennametal University

Certified as Six Sigma Black Belt from Automotive Component Manufacture’s Association

Advanced Total Quality Management course conducted by Prof. Kano

Professional Membership

Indian Institution of Industrial engineering, Quality Circle Forum of India, National Institution for Quality and Reliability, ABK- AOTS DOSOKAI Tamilnadu.

OVERSEAS TRAININGS

Attended training on “Low Cost Automation” conducted by AOTS, Japan at Yokohama. Benchmarking Best Practices visited to Japanese Industries

Attended workshop on “Surface and Contour Measurement” conducted by Hommelwerk, Germany

Visited TRW-Düsseldorf, Germany to study the suspension joints manufacturing process (Technical collaborator of Rane Madras Ltd)

Training on Lean Production System and Shop Floor Management in Bridgestone Japan.

Glass Manufacturing Process, Safety Practices, Employee Training System in Asahi Glass Company, Japan

Strategic Planning

Operations Management

Quality Management

Supplier Quality Assurance

Process Excellence

Plant Operations

Cost Optimization

Industrial Safety

People Management

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