Ref. No. : CA - 17902 - (Production - Moulding – with 27.1 years in Plastic Industry)

Education

Diploma in Production Management From Annamalai University. in 2004 to 2005

Post Diploma in Plastics Mold Design From CIPET Chennai in 1996 to 1997

Diploma in Mechanical Engineering From P.A.C.R.Polytechnic Rajapalayam in 1993 to 1996         

Skill Sets

skills and ability. I have in-depth knowledge of Plastics processing technology, Production management, Plastic Material, Mold & Machine Maintenance and Quality Assurance. 

supplier Quality Assurance :
Supplier Selection & Evaluation & Re-Evaluation. 
Conducting Audit - Supplier Process & Control methods.
PPAP/PSW Sign off at Supplier end.
Process Capability study analysis and Corrective action.
Product Validation & WI.
Supplier Training & Performance Monitoring.
Periodically Process & Product audit conducting at Supplier end.
Product / Process Development & 4M Changes Approval.

System Knowledge :
Good knowledge in MS word, Excel and PowerPoint presentation.

Work Experience

Deputy Manager Operations
Since Feb 2013 
Company Profile: Is an ISO 9001:2008 / TS 16949 certified group is one among the promising industry in the plastic injection mold and molding division. It caters with a strong presence in segments of Automobile, Electrical & Electronics, Engineering Products and Home appliances.
Job Profile:
Complementing production infrastructure functions independently on mold developing segment and processing segment.

Team Leader Operations
June 2010 to Jan 2013 
Company Profile: Leading player in injection molding plastic furniture and crates segments in India. Also Manufacturing & supplying wide range of injection molding products for automotive and appliances customers like Hyundai Motors India Ltd., Samsung India, Whirlpool And Valeo Lightings. It is an ISO / TS 16949:2009 certified company.


Manager Production  
June 2007 to June 2010
Company Name: United Industries. 
Company Profile: is catering Injection molded auto electrical 
Parts,NVH parts and Trim parts for Hanil Automotive ltd., and
Washing machine parts for SAMSUNG INDIA It is an ISO TS 16949:2009 certified company

Production Engineer 
June 2003 to June 2007
Company Name: Bright Brothers Ltd, 
Company Profile: leading player in injection molding plastic furniture and crates segments in India. Also Manufacturing & supplying wide range of injection molding products for automotive and appliances customers like HYUNDAI MOTORS INDIA LTD., WHIRLPOOL and TVS ELECTRONICS LTD.,It is an ISO / TS 16949:2009 certified company.

Production Supervisor
July 1999 to June 2003
Company Name: Southern Chromatics Pvt Ltd. 
Company Profile: is catering injection molded stationary parts like Pen,
Stampads,OHP markers to FABER-CASTELL INDIA LTD.,

Production Assistant
Sept 1997 to May 1999
Company Name: Valqua Products Ltd
Company Profile: Manufacturer and supplier of plastic molded components, specialized in components of vending machines, ceramic tile machines and all types of textile bobbins.

Career Snap Shots:
Establishment and optimization of the day-to-day operations of the plant including profitability, sales, expense, cost, quality and delivery.
Accountable for overall quality performance of manufacturing process in meeting the defined targets, in line with the management and departmental goals and objectives. 
Provides necessary definition, development and deployment of product Quality assurance strategy, addressing all phases of product development.
Conduct and supervise manufacturing process and product audit and follow up the corrective and preventive action plan.
Conduct training on QA, QC & HSE Systems. E.g. TQM, TPM, PDCA, 5S and KAIZEN.
Improve quality standards and maximize cost effectiveness by implementing competitive methodologies like 7QC TOOLS, Quality Circle, and PFMEA & POKE-YOKE.
Coordinate with internal customers on customer complaints and troubleshooting through PDCA, 8D, and SPC Methodologies.
Process parameters fixed with the support of DOE method.
Monitoring daily OEE report, Too history & breakdown history.
Ensure compliance to all relevant safety, quality and environmental management procedures and controls across the production section to guarantee employee safety, legislative compliance, delivery of high quality products/service and a responsible environmental.
Ensuring that all machines are operating as per the defined parameter to maximize of output and achieve efficiency.
Plan, organize and direct the manufacturing and maintenance operations which ensure the most effective return on assets. 
Meet all customer commitments through the production of timely, efficient and high quality products and service. 
Maintain Operation Team reports and provide information to sales representatives, customers and management with regard to delivery dates, schedules and operating problems.
Ensure the effective achievement of Operation department objectives through the leadership of the team – setting individual objectives, managing performance, developing and motivating staff, provision of formal and informal feedback and appraisal – in order to maximize subordinate and the performance of the section.
Planning/Scheduling in order to optimize production run time and achieve high levels of machine efficiency.
Ensuring that the break down and preventive maintenance of machines and plants are carried out promptly.
Preparing monthly MIS report to management. (Purchase vs. Sales).
Developed and maintained an effective organization and good working climate by organizing the staff into a working team of motivated employees.
Plan production capacity according to weekly and monthly sales projection
Monitor production vs. sales to review production schedule accordingly.
Coordinate with procurement officers and suppliers to ensure smooth supply of raw materials.
Ensure Compliance with company ISO/TS procedure.

Achievements: 
Sustain the Plant O.E.E above 80 % from February 2013 to till date.        (Target 85 %).
Production efficiency above 98 %. In fast six months.              (Target 100%).
Over all Rejection percentage maintaining 1.5% to 2.8%.                        (Working for reducing to 1.5%).
Through KAIZEN and SMED we achieved mold loading time       08 min     in 1300 T machine. (QMC used).
Achieved 100 % Internal Customer satisfaction.
Minimum 10% to 20 % of the productivity was improved in all new molds through KAIZEN & POKE-YOKE.
Reduced the attrition level by giving training and motivating the team.
Reduced COPQ through implementing TQM, Lean Manufacturing and KANBAN system.
Reducing Assembly line cycle time and skip-out issues by implementing censored semiautomatic assembly fixtures.
Avoiding off line inspection of products by improving the part inspection knowledge of operator.
Increases of business opportunity by reducing customer compliance through TPM, TQM, 5S and OJT.
There is no major accident happened in shop floor.
Meeting 100% Raw material yield.
Successfully implemented flash free mold system.
In 2011 one of the Housing mold was damaged by operator mistake, immediately we have repair the mold by reverse engineering & support the customer line without any stoppage.
Have visited CHINA on 2012 for Faurecia New project mold trial.

Additional Trainings:
September 2003 4 Days
Attended training program in the following QA systems by 
TVS ELECTRONICS LTD.,
Process capability study, Measurement System Analysis(MSA),
And Production Part Approval Process. (PPAP).
Systematic Problem Solving Techniques, 8D Analysis,5S and
                7QC tools.
Process Flow,FMEA,Control Plan, Design of Experiments and
Quality Cost.
Quality Systems And SIX SIGMA Methodology.

August 2004 2 Days
Participated in the training program on “Shainin DOE tools for
Manufacturing Problem Solving” conducted by TUV Rheinland
India Pvt. Limited.

September 2010 One Week
Participated in the training program on Lean Manufacturing, KAIZEN& 5S. conducted by TUV Rheinland
India Pvt. Limited.

Machine Exposures:
Vaste expérience  in  handling PLC controlled Injection molding machines like,
FERRROMATIC MILACRON – 300 T, 350T, 450T, 500T, 650T, 775T & 900T.
FANUC  - 150 T.
L & T - 50 T, 150T, 350T, 550T.
HSI  -  800 T & 2200 T.
FCS  -  150 T & 600 T
SUPER MASTER  - 450 T, 650 T & 850 T.
ENGEL - 330 T.
THOSIBA  - 280 T, 775 T & 850 T.
WINDSOR - 180 T, 350 T & 375 T.
VERTICAL  IMM - 50 T
Conventional machines - CNC LATHE, DRILLING, MILLING & EDM.

Mold Exposure :
Able to handle & service the below listed types of molds,
TWO/THREE PLATE MOLDS.
HOT RUNNER SYSTEM MOLDS.
SEQUENCE VALVE GATE MOLDS.
HYDRAULIC CORE MOLDS.
HYDRAULIC OPREATED SPLIT CAVITY MOLDS.
RACK& PINION SYSTEM MOLDS.
THERMOSET DIES.

Material Exposure:
In-depth knowledge in Processing the below listed Plastic materials.         
1. PPCP, PPTF, PPMF. 11. PPTF.
2. PPHP.             12. PBT.   
3.PPGF 10 to 40 %    13. PC.  
4. NYLON 6 & 66 GF.  14. POM. 
5. PVC.              15. LDPE, HDPE. 
6. PMMA. .           16. PET 
7.ABS                17.PS.
8. PC+ABS.           18. PPS.
9. SAN.              19. TPU.
10. HIPS.            20. TPE.  

Product Exposure:
PRODUCT RANGE
AUTOMOTIVE INTERIOR & EXTERIOR.
AUOMOTIVE LIGHTING LENS.
AUTOMOTIVE MIRROR & NVH PARTS.
REFRIGERATOR & WASHING MACHINE.
AIR CONDITIONER & LED TV PARTS.
PET PREFORM
PLASTIC CRATES
PAINT CONTAINERS 5L,10L,& 20 L

Customer:
HYUNDAI,RENAULT NISSAN & FORD
HYUNDAI,RENAULT NISSAN & FORD
HYUNDAI,RENAULT NISSAN & FORD
SAMSUNG & WHIRLPOOL 
SAMSUNG 
PEPSI
COMERCIAL USAGE.
ASIAN PAINTS.

Inprocess Quality Control: 
Process validation for fixing the Standard Process parameter and Work Instruction.
Monitoring change Management.
Process improvement & 4M changes approval.
Daily Top 5 rejection analyses & corrective action to achieve target PPM.
Monitoring COPQ.
Product and Process Audit as per TS standard.
Conduct Poison Cake Test.
Identifying Competency Gaps & Training. 
Process capability Studies & Layout Report monitoring as required.
Preparing Contingency Plan as required.

New Product Development: 
Addressing NPD Challenges.
Take snapshots of the design at major points during the process.
Collecting all the product documents, including all type of files and organize them in on easy to navigate folder structure.
Making a smoother transition from NPD to manufacturing NPI.
APQP for new Product.
PPAP/PSW Signoff with Customer.
ECN and NEW Tryout reports, Preliminary 
Process Validation / Cost Saving.
Poke – Yoke Implementation at the stage of NPD.
Monitoring & Updating ECN as required.

Customer Support: 
Responsible for Customer Relation and Requirements.
Monitoring & Doing Continues improvement for reducing Customer PPM (Achieved from 1000 PPM to “Single Digit” PPM.) 
On-time response for Customer complaints.
Quality Improvement Plan Preparation as per Customer requirement.
Handling Customer Audit / Effectiveness.
4M Changes Implementation.
Customer Specific Requirements Implementation.

Toolroom & Machine Management:
Ensuring Safe and correct 
tool / machine repair practices.
Ensure to follow the Work Order Instruction for corrective action.
Monitoring tool / machine history and PM Plan Vs Actual.
Monitoring Spare Management.
Periodically validate the tool/machine and allocate A, B, C & D grades according to the critical functions.
Plan to repair or change the spares as per the grades.
Monitoring MTTR & MTTF.
Monitoring and control over monthly optional budget for tool/machine maintenance.

Financial Management:
Preparing annual budget and capacity planning for Operation dept.,
Manage & monitor the operation budget ensuring the best value in all expenditure.
Doing Monthly and Quarterly assessment with financial team support.
Manage day to day processing of accounts and monitoring receivable Vs payable.
Reconcile monthly activity & generating year end reports for operation Dept., 

Future Goals

Looking for a challenging position to utilize and explore my potential towards growth and development of the organization. Learn each and everything that contribute best for the growths of the organization by continue developing and sharing my experience, skills and ability. 

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