Machine Plant

K. ASHOK

SENIOR MANAGEMENT PROFESSIONAL

PROFILE SUMMARY

Performance-driven professional with over 29 years that reflects pioneering expertise & year-on-year success in achieving business objectives in:

Production Operations Strategic Planning & Control Maintenance Operations Quality Assurance & Control New product development Process Enhancement Initiatives Budgeting&Expenses control Purchasing & Cost Control Warehouse management & Inventory control Vendor sourcing & Negotiation Customer Grievances Management Team Management

Specialties: Establishing Plant Operations/Projects/ Production Process/Quality Assurance/ Machines maintenance and trouble shooting/Arriving policies & Strategies/Budgeting(ZBB) & Cost control(EBITDA)

Expertise with QMS Systems(ISO/TS 16949, ISO/IATF 16949, ISO 45000(EMS 14001 &OHSAS 18001)), TPM and Kaizen techniques for loss elimination, cycle time reduction and rejection prevention, entailing identification of opportunities, analysis of data, cost benefit analysis, implementation and cost audits while executing the cost saving techniques / measures and modifications to achieve substantial reduction in expenditures & work within the budget.

Expertise in creating road map to achieve World class Manufacturing Excellence processes like Strategic deployment, Process Excellence, High Performance team, Performance Management: Lean practices like 5S, JIT, KANABN, SMED, TPM, POKA/YOKE, 7 Wastes, VSM,Visual controls, APQP, FMEA, CONTROL PLAN, MSA, PPAP,SOP, SQC, SPC, OEE, PIP etc...

Expertise in making Zero based budget and cost control by initiating and driving more projects in the area of manpower cost, energy cost, tools and consumables cost etc... KNOWLWDGE & SKILLS PURVIEW

Working knowledge, Skill and experience of the following: o In depth knowledge & Skills in Manufacturing process of :Bearings, fuel injection injector, connecting rod, Cylinder Block and Jacks, Metal forming, Sheet Metal and welding process o Implementation of TPM practices, ISO/TS 16949, IATF 16949:2016,ISO45001:2018(EMS 14001&OHSAS 18001),AS 9100D, Lean Manufacturing, Visual Control & Poka-Yoke, SPC, SQC Techniques, APQP, FMEA, CONTROL PLAN, MSA, SOP, PPAP and so on

o Executing Kaizens relating to machine productivity losses o Maintaining 5’s in the shop floor

o Expertise in OEE improvements and PQCDSM achievements o Expertise in Modifications in equipment, process flow, working practices, Tools& consumables, power etc. for line balancing for cycle time and controlling and reducing conversion cost per unit produced.

Hands on experience with Machine setting, Fixtures and Tooling, Gauging, troubleshooting & operations of all types of high precision machines and process such as: o CNC Machining Centres (SPM, VMC, HMC,BORING etc..) and Turning Centres o Cylindrical Grinding Machines

o Internal Grinding Machines

o Centre Less Grinding Machines

o Surface Grinding Machines

o Honing & Lapping Machines

o Auto Transfer machining and Assembly Line

o Presses(Hydraulic & Mechanical - from 80 ton to 1000 ton) and Press tools ORGANISATIONAL EXPERIENCE

07 March’18 - till LOKESH MACHINES LTD( Components Division)- Hyderabad as PLANT HEAD

( 2 Plants - Auto & Tractor - Cylinder Block Mfg)

Key Responsibilities:

1. Creating and implementing best practice manufacturing vision, strategy, policies, processes and procedures to aid and improve business performance

2. Heading the overall plant Operations - Productions, Quality, Maintenance,Process Engineering, Purchase and Stores. 3. Responsible to set the objective and KPIs to all direct reportees in line with plant objectives. 4. Monitoring the plant activities and drive the team members towards achieve the plant operations KPI. 5. Making Zero based budget and cost control by initiating and driving more projects in the area of manpower cost, energy cost, tools and consumables cost etc...

6. Develops plans for efficient use of materials, machines and manpower to achieve manufacturing cost, quality and inventory management targets

7. Responsible for OEE improvement & PQCDSM achievements. 8. Monitors customer delivery performance, cost reduction programs, lead-time improvements, and quality improvement projects that will enhance customer value and business unit results 9. Customer schedule adherence 100% with Zero defects. 10. Manages Fixture & tooling issues and conducts all safety and ergonomic related investigations 11. Customer satisfaction with focus on QMS/0 PPM/ COPQ 12. Ensuring safe and productive environment for all Business unit staff (Safety) 13. Drives continuous improvement (Kaizen &PIP) to extract best performance through Constant reviews on all parameters of the business and ensure appropriate counter measures are taken 14. Takes ownership of the manufacturing policy, guidelines and any associated documents 15. Reports on manufacturing activities on a regular basis to the Management team, ensuring accurate and timely reporting of the relevant Key Performance Indicators. 16. Deploying various methodologies to analysis processes and recommending modification to minimize losses, reduce rejections, reduce cycle time, Improve operating Efficiency, control variability and cost. 17. Implements various corporate initiatives and culture like Lean manufacturing system, TPM & 5S methodology among the workforce

Jul’07(From GREEN Field stage) – 21st Dec 2017

MAGAL Engineering Tech Private Ltd. (UK based MNC), Oragadam, Chennai as DGM – Manufacturing

(Connecting Rod and Jack Mfg)

Key Result Areas:

Assisting in managing the production operations

Ensuring the quality related concerns

Engaging in managing the maintenance and process engineering operations

Leading a team size of more than 150 people across different hierarchies and chains

Executing Total Productivity Management for the manufacturing areas; ISO 9000 & TS 16949 implementation and ISO 14001 implementation in the manufacturing cells

Highlights:

Successfully completed commissioning & installing of 2 Auto Transfer Connecting Rod Manufacturing Lines Projects which includes visiting General Motors, Opel Plant Germany, dismantling & packing, planning layout, reassembling machines, commissioning & installations, fixtures modifications, manufacturing planning, proving for dimensions and cycle time; thereby resulted in reducing the project cost to INR 30 crores against INR 120 crores for new machines

Performed various improvements & modifications like Introduction of New Axis, Conversion of Hydraulically Operated Job Centralized System to Solid Locators in all Stations to make this line for accommodating different variety of Con Rods (originally this line was designed to do 1 model of conrod) and for Quick Change Over; thereby resulted in: o Performing any number of conrod models as against one model o Setting changeover time is reduced from 2 days to 3 hours o Saving INR 80 Lakhs by introducing solid locators in place of imported ROHM Chuck

Successfully installed and commissioned Jack Assembly manufacturing line and stream lined the supplies to Jaguar Land Rover UK plant

Increased the productivity from 56% to 78% by:

o Reducing breakdown from 15% to 5% by introducing PM activities and maintaining critical spares o Increasing production output from 1500 to 2200 per day by improving fixtures & tooling and operators training o Decreasing rejections from 6% to 1.8% by performing continuous analysis and involving respective operators for taking responsibilities for their rejection

Reduced customer complaint from 50 PPM to 14 PPM by introducing more number of POKA/YOKE in production line

Saved the cost of INR. 46 lacs per annum by localizing imported Grinding Wheel and 3M Deburring Wheel PREVIOUS EXPERIENCE

Apr’03 – Jul’07 Delphi TVS Diesel Systems Ltd., Chennai as Senior Engineer /Sr. Manager ( FIE Mfg) Highlights:

Contributed in increasing the output for the following: o 1500 nos to 2200 nos. per day in Micromatic OD Grinding machine by modifying the dressing method o 3250 nos. to 4100 nos. per day in Curtis Face grinding machine by introducing a coolant chiller unit and there by reduced the cycle time from 24 secs to 19 secs

o 1950 nos. to 2350 nos. per day in Protek Internal machining by eliminating an operation o 600 nos. to 1000 nos. per day in DI Injector Assembly by introducing the dummy cap nut assembly method

Displayed excellence in increasing the following: o Injectors OLE from 70% to 85% by eliminating major losses and rejections o OPP from 20 to 25 nos. by reducing the cycle time and flow modifications (NAGARA System)

Steered efforts in reducing the rejections from500 nozzles to 30 nozzles and 800 Injectors per day to 100 Injectors by process modifications and Kaizens process

Merit of achieving the cost savings of INR 80 Lacs/ annum through indigenisation of about 30 tooling and saving of INR 10 Lacs by executing Kaizens in the cell

Put efforts in analysing the Overall Equipment Effectiveness (OEE) & Overall Line Effectiveness (OLE) and prepared action plans (6W+2H) to improve the machine effectiveness

Reduced the customer complaints from 10 to 3 complaints per year by introducing more Poka-Yoke and inspection systems in place; manufactured flow changed in Nozzle assembly area to fulfil customer requirements in 2 hours in advance time

Successfully launched new project while coordinating the VCO Nozzles for DI Injectors from Soft stage to Assembly at the cost of Rs.30 Crores

Presented efforts in managing a competent team through effective counselling and introduction of key performance indicators; thereby resulting in 200 Kaizens

Mar’91 – Apr’03 Lakshmi Machine Works (LMW) Ltd., Gummidipundi, Chennai as Engineer – Production Dept.

(Bearing Mfg)

Accomplishments:

Augmented the production of Top Roller Bearing Axles Ball Track Grinding (bottleneck operations) from 258 nos. per shift to 1600 nos. (620%) by improving grinding wheel performance and work holding modification

Increased the production quantity of:

o Jockey Pulley Bearing Axles Ball Track grinding from 1620 nos. per shift to 3000 nos by proving 4 components per cycle as against two components

o Jockey Pulley Bearing Outer Race Ball Track Grinding from 960 nos. per shift to 1600 nos by proving 2 components per cycle as against single component

Credited for reducing the department Rejection percentage from 8% to 0.5% by doing rejection analyses and involving the respective operators in the quality circle for making awareness among them on their own rejections.

Reduced customer complaint from 110 PPM to 28PPM by introducing more number of POKA/YOKE in production line

Saved cost of INR 180 lakhs/ annum achieved by stopping imports components (TR Axles) and tooling localization INTERNATIONAL PROJECTS

Frequently Visited Globally for machines Purchasing, training, trials and process study for the following Projects: o Honing Machines Purchasing for connecting rod big end bore – UK &Italy 2017 o Connecting Rod Manufacturing Process Study and Systems from SSANYONG Motor Company, Korea 2014/2015 o Connecting Rod Laser Scribing Machine Purchasing from ROFIN-LASAG, Switzerland 2013 o Double Disc Grinder Purchasing from C&B Machine Tools, USA 2013 o Connecting Rod Process Study and Machine Purchasing from General Motors Ltd., Germany 2012 o Connecting Rod Manufacturing Process Study and Systems from Ford Motors Ltd., England, UK in 2007 o Face Grinding Machine Purchasing from RETEC Machine Tools, England, UK 2006 o Precision Bulbous Grinder and a Head & Shank Grinding Machine Purchasing from Curtis Machine Tools, England, UK 2006

EDUCATION

2013 B.Tech. (Mechanical)

2006 MBA (Operations)

2003 BBA

1990 DME

IT SKILLS

Knowledge of:

oMSOffice Suite (MS Word, Excel and PowerPoint)

oWindows

oWeband Internet Applications

SEMINARS

Attended seminars on the following:

o JIPM TPM implementation by Sueo Yamaguchi San of JIPM including special seminar on Kaizens & 5S implementation and so on

o Implementation of Japanese technique like JIT, Kanban, 2 bins systems and so on o Principles and Tools of Toyota Production System - by IMTMA PERSONAL DETAILS

Date of Birth : 13th April 1970

Languages Known : Tamil,English and Telugu

Address : No.6, Pari Street, Kabilar Nagar, Manavala Nagar, Thiruvallur-602002, Tamil Nadu. Mobile : 91-944*******

E-Mail : ***********@*****.***

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