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  1. 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. 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. 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. 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%.

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