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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.
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
Certified as ISO 9000- INTERNAL AUDITOR by Madras productivity council.
Body building - 15 + years
Heavy vehicle assembly- OEM - 2.5 + years
Engine Manufacturing and CNC Machining – 4.5 + years
Powder coating - 1 years
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.
ERP, Auto CAD- 2000, SOLID WORKS, MS Office
Date of Birth : 25th
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
AREAS OF EXPERTISE
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.
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.
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 &
Kailash Vahan Udyog Ltd, Chennai Feb’2012 to till now
The organisation is Manufacturing of Tippers and Rigid bodies (Supplier to Daimler India commercial vehicles
Responsible for Entire production `activities (Weld assembly, Phosphate, Shot blast, Paint, Final and
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
Involved as CFT Member to various new model from proto, pre launch to till regular production in our
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 &
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)
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
- 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
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
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%.