1. Page 1
S. Mohan Kumar – Freelancing Consultant Profile
Cell: +91 9994456069 mohankumar_subramani@yahoo.com
Educational Qualification
Professional Summary
5/444, DWARAKA Nagar, 3rd Main, 3rd
Cross, New ASTC HUDCO Extension,
HOSUR – 635 109, TAMIL NADU
 Bachelor Degree in Mechanical Engineering (1986) University of Madras, Tamil Nadu
 Diploma in Mechanical Engineering (1980) State Board of Technical Education, Tamil Nadu.
Total Experience - Industrial, Consultancy & Teaching : 35 Years (1980 – 2016)
A) Industrial Experience: 28 Years
 M/s TECH AUTO Pvt Ltd, Unit II, Hosur – 7 Years as General Manager Operations, to take
forward on an offloading project of TVS Motor Company, Drum Rear Sprocket Machining.
CNC Machines & SPMs were shifted from three different locations of TVSM (Hosur Unit I,
Unit II & Mysore plants) to TECH Auto plant on phased manner. After the successful project
execution & commissioning of Cellular lines, self certified Finished Product supplies initiated
on JIT basis within 24hrs with PPAP sign off by TVSM QA Team.
 M/s MINDA Group of Companies, Hosur – 2 Years as Head Manufacturing – South
Projects, Commissioned Cellular lines to manufacture and supply of Handle Bar Assemblies
with central locking systems to TVS Motor Company, Hosur/Mysore & Enfield India, Chennai.
 M/s Rajsriya Automotive Industries, Hosur – 2 Years as Senior Manager Customer
Support & Quality Champion in sustaining Zero PPM at Customer end and ensuring JIT
supplies of all fabricated and powder coated parts. Also as Management Representative,
upgraded QMS to ISO/TS 16949:2002 as the first company in Hosur Industrial segment.
 M/s Sundram Fasteners ltd, Hosur – 2 Years as Module Manager – Cold Forging Divn,
responsible for manufacturing and supply of Four Wheeler Front axle CV Joints to DELPHI
Automotive system and actively participated in KOBATCHU KAIZEN Team for achieving
TPM special award from JIPM, Japan.
 M/s AGRIM Auto(promoted by ADEEP Group), Hosur – 2 Years as Senior Manager
Operations to support TVS Motor Company on an offloading project to enhance their volume.
Wheel Assy & Handle Bar Assembly lines were shifted from TVSM, commissioned and
initiated JIT supplies within 24hrs with PPAP sign off by Customer QA.
 M/s HARITA / ADEEP Group Companies, Bangalore – 10 Years as Senior Manager
Operations responsible for Manufacturing of Automotive locks in Cellular Lines using
concepts of 5S, TPM, TQM, JIT, POKA-YOKE, SMED, etc.,
 M/s Sundram Clayton, Moped Divn, Hosur - 3 Years as Production & Quality Engineer in
Engine Components Manufacturing lines.
B) Consultancy Experience: 3 Years in Lean Manufacturing Implementation at Hosur &
Bangalore Industries in tie up with the leading Lean Consultants form Chennai & Bangalore
C) Teaching Experience: 4 Years as Lecturer at Engineering Institutions at Salem.

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Acquired Skill Sets & Future Visions
1. From the beginning of the carrier as an Engineer, experienced in various manufacturing processes like
‘Precision Machining’, ‘Die Casting’, Plastic Injection Moulding’, ‘Tool Design & Manufacturing’,
‘Cold & Hot Forging’, ‘Conventional Press Shop & Turret Punching’, ‘Fabrication’ & ‘Plating and
Powder Coating’.
2. Having reached to Managerial positions, started concentrating more on Production Engineering and by
practicing Automation Principles, erected many Cellular manufacturing lines to increase productivity.
3. With the hands on experiences as Senior Management, played a major roll between Tier-1 Companies
& TVS Motor Company to set up new Cellular manufacturing line facilities around the OEM premises
to feed the sub-assemblies required for the vehicle assembly on Pull System basis. As a Plant Operational
Head, initiated JIT supplies in alignment with the Takt Time on different product variants.
4. During September 1996, visited M/s USP Lock Corporation, USA for a Technical Tie up and promoted
export business opportunity.
5. During October 1998, visited TAIWAN to inspect and clear an Automatic Lock Barrel Assembly
System and proved the machine to ensure the planned Buy Back Period of the equipment within 3 years.
6. Have a long vision to develop the Top Management and Middle Management Teams, Supervisors,
& Workmen in many of the Large, Medium and Small scale segments in the Southern region on
“Lean Manufacturing Platform”.
7. Professionally willing to guide the “Bachelors and Masters of Engineering” final year students
towards strengthening their knowledge on the basic manufacturing principles like TPM, TQM and
LEAN and preparing themselves for the comfortable entry into their targeted industrial segments.
Hand Holding Lean Manufacturing Consultancy / Training engagements
undertaken for some of the Companies in Hosur & Bangalore.
Name of
Company
Size of
Company
Training/
Consultancy
Provided
Duration Project
Cost
Lean Tools
implemented
Benefits to the
Company
M/s Neel
Auto Pvt
Ltd, Plant II,
Hosur
Medium
Training &
Workshops
6 days 0.6 L
Problem Solving
Tools & Root
Cause Analysis.
Supervisors with
Associate group trained
in workshop to use
“PST” to reduce
Process rejections on
their respective lines.
M/s TITAN
Company,
Hosur
Large
Training &
Workshops
6 days 1.0 L
Problem Solving
Tools &
Techniques for
TITAN Vendor
CFTs.
TITAN Vendor CFT
trained to apply PST
using their respective
company rejection
datas during the
workshop.
M/s Sandvik
Asia, Hosur
Medium
Training &
Workshops
6 days 0.6 L
Value Stream
Mapping(VSM),
KAIZEN &
SMED.
Companywide
Employees understood
& prepared VSM for
their respective lines
and identified the
bottle neck areas.

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M/s RIDA
Industries,
Hosur
(Captive
Vendor to
TITAN)
Small
Training &
Consultancy
9 Months 6.0 L
5S, Safety,
Motivation, TEI,
POKA-YOKA,
KAIZEN, VSM,
FLOW, SMED,
TPM, PST, Line
Balancing, Cycle
Time Reduction &
Visual Controls.
1090 SQFT (10%)
Space saved after 5S
Implementation; 100
KAIZENS Magazine
released; Lead time for
manufacturing
reduced from 26days to
17days; Change over
time reduction – 22%.
M/s
VASITA
Industries,
Hosur
(Captive
Vendor to
TITAN)
Small
Training &
Consultancy
9 Months 6.0 L
5S, TEI, Safety,
Motivation,
KAIZEN, POKA-
YOKA, VSM, ,
SMED, TPM,
PST, FLOW, Line
Balancing, Cycle
Time Reduction &
Visual Controls
Change over time
reduction – 42%; Lead
time for
manufacturing
reduced from 7days to
4days; 654 SQFT (7%)
Space saved after 5S
Implementation 78
KAIZENS completed
M/s RELIC
Industries,
Singasandra,
Bangalore
(Vendor to
TITAN)
Small
Training &
Consultancy
1 Year 8.0 L
VSM, FLOW,
5S, Safety,
Motivation,
SMED, TEI,
POKA-YOKA,
KAIZEN, TPM,
PST, Cycle Time
Reduction, Line
Balancing, VCS
435 Hrs Setting Time
saved per year; 500
SQFT (5%) Space
saved and released for
new Canteen after 5S
Implementation; 50
KAIZENS completed;
M/s SONA
Horologicals
, Hosur &
M/s SONA
Band,
Bangalore.
(Vendors to
TITAN)
Small
Training &
Consultancy
1 Year 8.0 L
5S, Safety,
Motivation, TEI,
POKA-YOKA,
KAIZEN, VSM,
FLOW, SMED,
TPM, PST, Line
Balancing, Cycle
Time Reduction &
Visual Controls
Lead time for
manufacturing
reduced from 7days to
4days; Change over
time reduction – 42%;
654 SFT (7%) Space
saved after 5S
Implementation 78
KAIZENS completed;
Date: 11.06.2016 Signature
Place: Hosur