1. P.MURUGAN
Mobile: 09677126908 E-mail: pmurugan25@yahoo.com
Career Objective:
Seeking assignments in operations in Automotive industries, which provide excellent opportunities to utilize my
potential and thereby improving my carrier as well as beneficial to the organization.
PROFESSIONAL PROFILE
 Technically accomplished professional Graduate with 20+years experience in Production Management in
Automotive industries, currently working in KAILASH VAHAN UDOG LTD, as Manager – Production.
 Experience in handling team of more than 200 qualified/semi qualified personnel
 Adept at people & production management, productivity improvement, decision making
 Accurate, efficient & methodical in handling assigned tasks, posses excellent problem solving & analytical
abilities
 Certified as ISO 9000- INTERNAL AUDITOR by Madras productivity council.
INDUSTRIAL EXPERIENCE
 Body building - 15 + years
 Heavy vehicle assembly- OEM - 2.5 + years
 Engine Manufacturing and CNC Machining – 4.5 + years
 Powder coating - 1 years
TEHINICIAL SKILL
 MIG Weld, Dip Phosphate ,Auto spray phosphate, Shot blast, Paint, Trim and Dispatch
 Chassis , vehicle and transmission assembly
 Engine assembly, Engine testing
 Powder coating, auto parts assembly
 Quality system ISO 9001:2000, ISO TS 16949:2009
 KAIZEN, POKE YOKE, 7 QC Tools,5S and ANDON PULL SYSTEM
 Capacity planning, Line balancing technique, PFMEA, PFD, SOP.
 CNC Machines (Programming &Practices).
EDUCATION & CREDENTIALS
BS Engineering with First Division
Birla Institute of Technology, Pilani in 2007-2010
Diploma in Production Management with First class
Annamalai University, Chidambaram in 1998-1999
Diploma in Mechanical Engineering with First class
T.P.E.V.R Periyar Govt Polytechnic, Vellore in 1988-1991.
IT Skills:
ERP, Auto CAD- 2000, SOLID WORKS, MS Office
PERSONAL DETAILS
Date of Birth : 25th
June 1973
Father’s Name : P .Perumal.
Marital status : Married
Passport : Valid till 2020
Language Known : Tamil, English &Hindi
Communication Address: No 6, Bojakara cross street, Walajabad, Kanchipuram-631 605

2. AREAS OF EXPERTISE
Production
 Overseeing production related tasks includes, planning & troubleshooting for achieving the planned as per
schedules. Key focus is on achieving bottom line profitability by ensuring optimal utilization of resources.
 Diverting mainline activities in Assembly Line to Sub-Assembly with a view to reduce takt time and
debottlenecking wherever possible.
 Process Engineering by reduction by up streaming/down streaming various activities in the production process
stability and line balancing.
 Incorporating child parts to the Assembly line as Sub assembly to ensure smooth function of Main assembly.
Quality
 Interacting with the Quality Department for detection of potential deficiencies and implementing corrective
and preventive action. Maintaining Quality Systems and Process Control Records.
 Directing and guiding improvement projects under TQM activities.
 Assuring conformance of the product to safety norms and specifications.
People Management
 Ensuring the development skills, abilities to cell members and officers through training & deployment of
projects, also guiding & facilitating them to achieve the desired targets in DWM- PQCDSM
 Coordinating with the HR department in conducting negotiations with labour unions towards resolving issues /
grievances and maintaining amicable employee relations.
 Directing, leading & motivating workforce, imparting continuous On Job Training for accomplishing greater
operational effectiveness/ efficiency.
 Working on succession planning, shift management activities, appraising the member’s performance &
providing feedback.
CAREER HIGHLIGHTS
Kailash Vahan Udyog Ltd, Chennai Feb’2012 to till now
Manager- Production
The organisation is Manufacturing of Tippers and Rigid bodies (Supplier to Daimler India commercial vehicles
pvt Ltd.)
 Responsible for Entire production `activities (Weld assembly, Phosphate, Shot blast, Paint, Final and
Dispatch).
 Initial assignments is Body integration INCHARGE at customer end on behalf KVUL and production
streamlined from 0 to 20 per day output within six month , after that these production operation handed over
to Daimler.
 Involved as CFT Member to various new model from proto, pre launch to till regular production in our
plant.
 Implemented KANBAN System to deliver bodies as per customer LIP
 Team member of ERP system adapted in manufacturing in 2014
 Team member for, first time get ISO TS 16949;2009 Certificate in 2015
 Rigid body SKD productivity improved by change fixture position from horizontal to inclined position,
which reduced operator fatigue and improved efficiency
 Changed batch production to Line production to meet customer schedule.
 Costs saving in weld shop and paint shop by implementing advance equipments, operator training and
monitoring daily, weekly, monthly review system.
 Tipper project successfully implemented on 2014 and productivity improved 10 per day.
 Tipper SKD manufacturing started in house and stopped other KVUL Plant supply.
 Proposed and implemented Cost reduction ideas, which directly reduced 3% of body manufacturing cost.
 Eliminated NVA in rigid body at BIW stage ( Mudguard fixing and removing, missed area welding &
grinding)
Rajsriya Automotive Industries Pvt Ltd, Hosur. March’11 to Jan 2012
Manager – Operation
The organisation is manufacturing of Auto Components (Tier 1 supplier to TVS, SONA, and RANE NSK)
• Heading operation of Weld shop, Assembly, Powder coating and Despatch.
• Productivity improved 40% in Powder Coating by modifying conveyor Jig
 Quality pass level increased from 96.5 % to 98 %.
Simpson & Co Ltd (Amalgamation Group), Chennai. Since June’09 to Feb’ 11
Assistant manager – PRODUCTION
The organisation is manufacturing of Diesel Engines (S3 series, S4 series, Tata Cummins, B3.3 Cummins)

3.  Core team member of B 3.3 Cummins engine for Source approval Project
 Prepared SOP, PFD, and PFMEA for B3.3 Cummins Engine for Entire process (Machining, Assembly, and
Testing) upgrading on regular basis.
 Layout planned and implemented for outside J HOOK assembly process (Engine finishing, leak Test, Hot
testing, and phosphate, Painting, EFD and Despatch)
 Engine testing process cycle time reduced from 50 Minutes to 30 Minutes by provided innovative solution
( water inlet, outlet and return , Fuel inlet & return, Lube oil connections items modified).
ASIA MOTOR WORKS LTD. (Essar Group, Gujarat) Since Jan’07 to May ’09
Deputy Manager – PRODUCTION HCV ASSEMBLY
The organisation is OEM of Global Truck series (Heavy Commercial Vehicle), LCV and Auto Components.
 Formulated and manned the chassis Assembly Shop ,started production and reached rated production 6
per day in order to supporting Truck Main Assembly plant in early stage Contributions included:
Created process flow, SOP, Lay out, Man power requirement for Producing 9 HCV models and success
fully implemented in frame assembly
Manpower Productivity improved in Assembly 13% per month by resolved Quality issues and Operator
training.
- Cycle time reduced from 4 hrs to 3 hrs per frame by created sub Assembly for Bogie cross member
 Augmented Production capacity from 5 per shift to 25 per shift in 2 years by bringing innovative solution.
 Identified and eliminated NVA in Valves assembly station, which reduced cycle time 10 minutes and cost
saving Rs.200 @ Vehicle.
 De- bottle neck done , while implementing 4923 TR / 4018 TR ABS assembly in line by creating S/a of Bundle
Hoses for air line system in line and Identified Quality issues and eliminated along with CFT,in this
improvement line cycle time came down 30 mints from 60 mints.
• Improvement in the manpower productivity in Assembly area by bringing innovative solution and achieved
around 33% productivity improvement every Year in Last two Years.
• Working as a Core team member in improving the assembly quality and achieved the direct pass level of 95%
from 70 % under Leader ship of Production HEAD.
• Created and Driving the Continuous Improvement Team (CIT) and enhanced the level of Kaizen from 1 to
1.5 per 110 persons working
 Actively participated in the CRE MANTHAN-2008. Distinction of rendering 50 Ideas for cost reduction of
vehicle produced, till date.
 Created POKAYOKE for fuel tank mounting bracket sub assembly for occurrence defects and reduced from 5
per week to Zero.
AUTOMOTIVE COACHES AND COMPONENTS LTD., Chennai April 95 toDec’2006
Executive- PRODUCTION
A JV of Ashok Leyland and TIDCO, the company manufactures After Chassis Products, BUS, Tippers, Cargo
Bodies, and Front End Structures.
 Opportunity to Lead Paint, Trim / PDI Dept within 6 years of Joining as Act apprentice
 Productivity improved in Trim and paint shop by implementing Pre Fabrication Process instead of as like ship
building process. Achieved 300 % of production improvement within two year from July2004 to March 2005.
 Developed competency of employees for special process to ensure 100% production achievement in trim to
ensure customer commitment in PDI by imparting training to Skilled operator / Semi skilled operator
 Eliminated NVA activity as welding work after painting, which reduced 2% of body total process man hrs. in
Trim /PDI by corrective & preventive action,
 Implemented operator self certification, MORE Q Badges matrix system for operator , due to this Vehicle
quality improved ( Final Vehicle Demerit points comedown from 500 to 180)
 Successfully implemented Quality System ISO 9002: 1994 in the year of 1999 and ISO 9001: 2000 in the year
of 2002 further ensuring compliance & up gradation of the systems to improve the operating efficiency.
 Suggested and implemented, Electrical cable dia 5mm to 4 mm for auto electrical lamps in vehicle, cost saving
Rs.25 per vehicle.
Rewards & recognition:
 Appreciation certificate for Quality of my work in Tipper trim Dept on Nov 2003 by GM Mfg / GM F&S.
 Appreciation certificates for continual improvement in both Tipper trim shop and paint shop during CI
competition held on July 2006.
 Appreciation letter received from GM Mfg for maintained 5S in trim shop.
 Received the Top Merit Rating Continuously in the annual appraisal from 2002- 2006.
SHYAM ASSOCIATES., Chennai June’ 91 to Oct’ 94

4. Supervisor - Quality
Manufactures of Turned Industrial Component and Fabricators
 Implemented sample inspection in CNC Turning and Machining line, instead of 100% inspection.
 Direct pass level of components increased from 70% to 95%.