Sureshkumar Muthumari

Phone : +918********* Email : ady6c0@r.postjobfree.com

social media : www.linkedin.com/in/sureshkumar-muthumari Skype ID: sureshmfg

PROFILE SUMMARY:

Manufacturing Engineer with more than 10 years of overall experience with more than 9 years of experience in wind blades manufacturing in process engineering in process improvement / validation, prototype builds, new product launch and new product introduction and technology transfer and tooling’s development, Process Design CORE COMPETENCIES:

Process Improvement, Process flow diagram, DMAIC, Kaizen, Root Cause Analysis, AutoCAD, MS Office, PFMEA, BOM management and CAPA, Wind chill (PLM), Tooling’s development, Statistical process control (SPC),7QC tools, Composites Process development, Composites Validation.

EDUCATIONAL QUALIFICATION:

Bachelor of Engineering in Manufacturing Engineering - Central institute of Plastics Engineering and Technology, Anna university – April 2014– Chennai.

Diploma in Mechanical Engineering –Tamilnadu Polytechnic College – October 2009 – Madurai.

SSLC -TVS Sundaram Matriculation School – March 2006– Aviyur. PROFESSIONAL EXPERIENCE:

Assistant Lead Process Engineer - Blade Assembly, Finish & Add-ons Vestas Wind system R&D Chennai, April 2022 – present Key deliverables:

Prepare Process verification Procedure (PVPR) for Prototype builds according to product Design requirements and closely work with prototype technicians for verification throughout the builds.

Create and Revise PFMEA’s assessing all failure modes in process and define actions for risks with high action priority number accordingly and follow-up for action closure with all stake holders including Process Work instructions update.

Analyze the existing repair methods for new product and update repair specification in Blade Repair Specification (BRS) document as required during prototype builds

Analyze Product and Process requirements and update manufacturing requirement specification (MRS) document as required during design prototype builds.

Define and update Process CTQ list for verification of critical process requirements at each stage.

Prepare and follow up for all technical documents approval from functional leads including product drawings and Process Verification documents and Test paper for each prototype build.

Attend RCA meetings for critical NC’s and define and implement actions to eliminate critical defects.

Review and Provide inputs for 3D and 2D drawings update required to CAD team to deliver the design changes without delays for each Design Prototype builds.

Technical lead support to Tech transfer projects for built to print blades.

Capture all Lessons learnt and create actions along with all stake holders to improve the design and process and share across to implement lessons learnt for new blade projects

Review and Provide inputs to DFMEA with process learning are at each stage of Prototype builds.

Work closely with New Product Master Team (NPM) for Process Work instructions

(PWI) update to meet maturity assessments requirements at each stage of Technical Review according to vestas way to market.

Create Process verification Plan (PVPL) to validate critical process and product requirements during prototype builds.

Review all tooling’s and provide inputs tooling team for tooling issues and challenges observed and improvement of existing tooling’s for making more robust process.

Raise Deviation reports as required to update gaps in Process documents and Drawings during design prototype builds.

Closely working with NDT team to evaluate assembly results for each blade and take actions for assembly defects through document updates.

Provide On job training to shop floor team for each process with process work instructions in each build and technical support for shop floor issues. Senior Process Engineer– Engineering

TPi Composites India Pvt Ltd, Chennai - May 2019 to April 2022 Key Deliverables:

Engage in engineering prototype builds to create process flow diagrams (PFD), creation of process work instructions (PWI)/SOP and BOM preparation according to technical drawings during launch and pre-serial and maintain /revise during serial production.

Ensure all critical design parameters defined as C-CTQ/S-CTQ and critical process requirements as P-CTQ covered in PWI, PFMEA during proto-builds and validation during launch to pre-serial.

Closely working with cross function teams to create/revise PFMEA/Control forms/Control plans

Create and validation of Process verification and validation plan (PVPL) for new assembly process during launch.

Tooling’s/Fixtures definition, development and validation during prototype and pre-serial and working with global design team for new tooling’s.

Identify and drive continuous process improvements projects like defects reductions, cycle time reduction using process optimization using SPC tools and manpower utilization and cost reduction projects implementation.

Providing technical supports to production team in analyzing and troubleshooting major issues related to tooling’s in assembly and supporting production cycle time ramp ups as required.

Prepare Root cause analysis (RCCA) for critical and repeated non-conformities (NC) and updating the PFMEA with corrective actions to prevent the re-occurrence of the defect.

Handling of change managements and implementation of ECO’s from the customers within timeline and preparing trial deviations request for new process and material trials.

Perform Layered process audits (LPA) and support for VDA 6.3 audits from customer.

Technical Training of PWI’s to operators and staff’s during proto builds and serial production and prepare one-point lesson for technical explanations.

Work with EHS team to ensure safe working conditions and compliance with health and safety legislations.

Process Engineer–Process Engineering

Siemens Gamesa Renewable Power Pvt Ltd, Nellore –March 2016 to Aprils 2019 Key Deliverables:

Lead and manage the process of technical transfers including process development, ramp up and new product introduction (NPI) from development to manufacturing and between internal and external factories.

Create visual work instructions (VWI) and Work instructions (WI) and standard operating procedures (SOP), Process flow diagrams (PFD) for new processes and methods.

Developing new composite components processes and validation during prototype and pre-serial manufacturing.

Proactively monitor, identify, develop, and implement improvements in process and Tooling’s/Fixtures (Layup, infusion and assembly) and technical supports to production.

Perform process audits to review critical product characteristics and process variables and implementing sustainable corrective actions for process issues

Providing technical training for new equipment, process &procedures to production technicians and staffs.

Working with CFT team to prepare PFMEA, Root Cause Analysis and 8D during prototype builds and pre-serial.

Define and develop Jigs and Fixtures for new products manufacturing and validation during prototype manufacturing in line with global tooling team.

Curing process validation and ensure product requirements fulfilled during infusion and Assembly.

Junior Engineer – Production

VRV Asia Pacific Pvt Ltd, Chittoor– November 2014 to March 2016 Key Deliverables:

Plan, lead and supervise to ensure on-time delivery by elimination of major bottlenecks in fabrication process.

Participate in the new product design ad put forward reasonable opinions and improvements based on the manufacturability and mass production planning.

Work with quality department to ensure fabricated parts meet design specifications in each stage of fabrication as per quality assurance plan (QAP).

Improve manufacturing efficiency by analyzing and planning workflow, space requirements, and equipment layout.

Responsible for fixture design, maintenance, and process verification as per SOP definition and reduce cost by implementing automation in fabrication setups.

Problem solving during daily production with root cause analysis and counter measures implementation to prevent re-occurrence.

Production documentation handling, including logbooks and Standard operating procedures (SOP)

Junior Engineer Trainee – Production

Win Wind Power Energy Pvt Ltd, Chennai – Nov 2009 to July 2011 Key Deliverables:

Planning day to day production activities to achieve the maximum production.

Co-ordinate with QC for quality clearance of inward materials and stage by stage production acceptance.

Identify and improve manufacturing profitability through productivity improvement, waste reduction and safety improvement through kaizen implementations.

Ensure operators work accordingly to work instructions (WI) and provide technical support to them.

ONSITE PROJECTS AND TRAINING:

Technical Training for G132 3.3 MW wind turbine blades prototype manufacturing for two weeks at Siemens Gamesa Renewable Energy, AOIZ, at Navarra, Spain.

Worked as Industrialization Engineer responsible for G132 3.3MW launch and prototype manufacturing and technology transfer for five months at Siemens Wind Energy Inc, Fort Madison, USA.

Worked as Senior Process Engineer responsible for V150 4.2MW launch technical training and prototype manufacturing for seven months at TPi composites ltd, Turkey.

Technical Training for V150 4.2 MW wind turbine blades manufacturing for one week at TPi wind turbine ltd, Yangzhou, China.

ACHIEVEMENTS AND AWARDS:

Best kaizen Award for 2019 at Siemens Gamesa Renewable Power Pvt Ltd.

Best employee Award for 2019 at Siemens Gamesa Renewable Power Pvt Ltd.

Reduced cycle time of blade from 36hrs to 24hrs by identifying continuous improvements projects and lean manufacturing implementation along with cross functional team at Siemens Gamesa Renewable Power Pvt Ltd.

Best performer Reward for Assembly defect reduction and cost reduction for 2020 at TPi Composites India Pvt Ltd.

CERTIFICATIONS:

Lean Six Sigma Yellow belt (DFSS) (No expiration)

Lean Six Sigma Green Belt (DMAIC) (No expiration)

APQP4 Wind specialist (Expiration –Sep 2023)

IMS Internal Auditor ISO 9000,ISO 14001 & ISO 45001 PERSONAL INFORMATION:

Father’s Name S. Muthumari

Date of Birth 27.09.1990

Nationality/ Religion Indian/ Hindu

Marital Status/ Gender Married/ Male

Languages known English, Tamil

Address 3/135, East Street, Aviyur, Virudhunagar (DT), Tamilnadu, India Pin code: 626106

Passport Number : N5396362

DECLARATION:

I hereby assure that information furnished by me is true. Date: 22.08.2023 Yours sincerely,

Place: Chennai Sureshkumar M

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