1. Over 15 Years of Experience as LEAN & Industrial Engineering ,Production Engineering,
New Product Development
In TVS Motor Company, & Hi Tech Gears Ltd.& Varroc Engineering,Faiveley
S.Rajasekar
G-4 , Classic Homes. Matham road , Hosur
sr_rajasekar@yahoo.co.in Cell:9486593321
CAREER OBJECTIVE
Accelerate continual improvement in organization performance by leveraging on professional
experience acquired over 15 years in various field.
JOB OBJECTIVE
Seeking senior level assignments in Production Engineering, New Product Development and
Project Management with an organisation of repute
BRIEF OVERVIEW
• Expertise in managing diverse range of activities such as new plant development,
process & equipment selection, capacity planning, process control, cost management
and quality assurance
• Proficient in developing & streamlining systems with proven ability to enhance
operational effectiveness and meet operational goals within the cost, time & quality
parameters
• Deft in implementation of quality standards such as Total Quality Management, Poka-
Yoke, QS 9000 / TS16949, TPM, ISO: 14000, IRIS, sound understanding of concepts of
PFMEA, and Tooling Development
• An effective team leader with strong analytical, planning, troubleshooting and problem
solving skills
• Thoroughly experienced in all aspects of LEAN(Toyota) Manufacturing Systems.
• Drafted & improved Valuestream Mapping & Spaghetti Chart of 5 Mini Factories.
• Implemented BIGISLAND formation and RABBITCHASE in Assembly & Machine Shop.
• Significant experience in Time Study, Line Balancing, Manpower Calculation and
Capacity Calculation.
• Successfully implemented STANDARDIZED WORK PRACTICE in Gear machining cells .
• Reduced Manpower by using MTM METHODS & LOW COST AUTOMATION.
• Hand experience in New project implementation & execution of Delhi metro trains.( Brakes system,
Pantographs, HVAC, Acess &Information)
i
WORK EXPERIENCE
Area of strength

2. FAIVELEY TRANSPORT RAIL TECHNOLOGIES INDIA LTD. - HOSUR
The Faiveley group is one of the world leading suppliers of railway system and services
with six major product lines. Brake systems, Couplers, Air dryer, Pantographs, Doors,
HVAC, Air suspension systems, Compressors. Faiveley is a French based company
having 40 entities in 20 countries, head quartered at Paris.
Manager Manufacturing Engineering .- Hosur. Nov ‘07 till date
REPORTING TO : VP MFG
Roles & Responsibilities
 Holds the distinction of developing new facilities for enhancing capacity of all plants
and for meeting requirements of new products
 Set up Manufacturing Facility from scratch involving preparation of CAPEX budget,
new product introduction, quality improvements, cost reduction and capacity
enhancement
 Handling of process Engineering team 11 members.
 Develop KRA and KPI for process engineering departments with respect to company goals
 Responsible for increasing productivity through combined work steps, removing non-value
added tasks, adding automation and the development of effective work practices through
VSM .
 Review of Day to day manufacturing line issue with team members.
 Capacity planning for all manufacturing cells depending upon the demand
 Resourceful in organizing project QRQC, PFMEA and come up with mitigation
plan to solve the blocking issues.
 Guiding the delivery team on the obligations and managing contractual
documentation.
 Handling of customer Enquiries.
 Working closely with Suppliers to ensure the project meets business needs.
 Liaising with cross-functional departments viz Finance & Accounts, Purchase,
Production and R&D to complete the project within the deadline.
 Inter-departmental coordination for any queries from customers for smooth execution
of project.
 Responsible for Project Planning, Scheduling and Monitoring the assigned project with main
focus on
 “On time delivery", using MS project tool.
 An effective communicator with customer to fulfil the deliveries of contractual obligation on
time.
 Hand on experience in APQP tool to clear contractual milestones of project.
 Established work package, cost, hours on project as per the appraisal of the project.
 Organise weekly project QRQC on open points, to make correct decision at right time.
 Preparing the manufacturing layout for commissioning the machines
 Conducting periodically Review of Layout optimization with shop floor team
 Conducting micro motion study of processes to achieve better line balancing
 Responsible for Planning and execution of new Projects/Process Development
 Preparation and standardizing manufacturing processes required for new products through
documents like Flow Charts, PFMEA, Operation Standard.
 Responsible for validation of new process .and establishing process in all manufacturing line.
 Performed time studies on production equipment to successfully establish production
bottlenecks
 Achieving breakthrough cost reduction projects and Optimizing Process Settings
 Responsible for Kaizens implementation across manufacturing process
 Developed a set of guidelines to reduce costs in the division through value improvement
programmes
 Implement design changes. Initiate methods and process improvements

3.  Lean Co ordinator for Faiveley Indian operations.
 One of the Project members in Chennai& Delhi ,Kochi Metro Rail projects for
handling Brake Application , HVAC ,Acess & Information System.
Achievements
• Instrumental in reducing cost from Rs. 30.2Crores to Rs. 24 Crores through
optimisation of plant layout and by reducing the building size from 90Mx40M to
60Mx32M
• Initiated continuous improvements - Kaizen practices in the day today management in a
schedule manner, and included the plan Vs achieved measure of continuous improvements
inthe weekly /monthly reporting. Thus achieved an annual savings of Rs.2.8cores in
2010-14.
• Achieved top score i.e., 83% among the group companies during last year as per Faiveley
manufacturing system which is audited by HQ adapting Lean tools.
• Implemented 12 Transfer of Technology projects with lean manufacturing system .
• Achieved Cost saving through TOT project 25.8 cores per year.
• Implemented 22 VSM projects ( 2008 to 2015)and cost saving 6.8 cores.
• Implemented 6 Automated Test Bench for New projects.
• Established New manufacturing plant at Baddi( HP) – 2007 to 2008.
• Established Multi Products line Brake division .
• Improved the Productivity to35% in Brake panel products.
• Improved productivity 38% in HVAC Assembly line.
Varroc Engineering Pvt Ltd, Aurangabad & Pune.
Varroc has 17 plants all over India, Most of our plants are certified for TS16949. Company
also adopts best manufacturing practices like TQM, TPM, SAP etc., and marching towards
become a world class company. Major customers are Baja Auto Ltd.,General motor, Remy,
Saufrdanfoss, Scarpa & Colomba etc. Presently company is venturing into export business
and targeting 50% business through exports.
Asst Manager Corporate QA - TPM &IE – Jan ’06 to Oct ‘07
REPORTING TO : VP- SPECIAL PROJECTS
Roles & Responsibilities
 Responsible for Co-Ordination of 8 Pillars TPM activities in Metallic Division Guidance by
JIPM consultant Mr.S.Yamaguchisan.
 Responsible for Effective utilization of existing resources and cost effectiveness in
the Operations.
 Coordinate with the TPM circles for making project plans and daily activity plans and
monitortheirprogress towards Zero losses, throughput increase and yield
improvement the focus would be of continuous Value addition and waste elimination.
 Responsible for cycle time reduction, Capacity Enhancement and Re-Engineering.
 Responsible for conducting system & process audit and Implementation
 Responsible for Audit promotion progress and the education and cultivation of employees.
 Responsible for Implementing TPM & Cultural change in organization.
 Responsible for implementating Kaizen & Suggestion scheme.
Hi Tech Gears Ltd., Manesar
It is a 750 crores, Automobile Transmission & Robotics Systems Development company in
collaboration with GETRAG, USA & HONDA, JAPAN. It has six units in India and supplies products
to VOLVO, FORD, CUMMINS, MUSASI, BOSCH, and HONDA etc
Kaizen Leader (LEAN-TPM) Aug 2003 – to Dec 2005
REPORTING TO : GM- LEAN TPM

4. Roles & Responsibilities
 Responsible for Coordinator of TPM activities in New Plant at Manesar. (Guidance’s byJIPM
Consultant Mr. Mizota)
 Preparation of Layouts and Line balancing of Gear Machining cells.Estimation of Standard cycletime
& Manpower Requirement Planning.
 Preparation new projects Too lings & Fixtures
 Preparation of image plan of plant (Visual Factory & System).
 Establish Overall Material Handling of Plant (Supplier & Customer Loop)
 Preparation & Layouting of Gantry Automation – Turning Machines.
 Preparation of Internal and External Logistics.
 Process capability studies for Machines Operations.
 Process / Quality improvement of products by solving batch problems.
 Analysis of machine down time & upgrade the system.
Achievements
• Enhanced Output from 3000nos to 7000nos by Re-engineering & Low Cost
Automation. (Rapid Improvement Workshop)
• Improved productivity to 20% by formation of Big Island in Honda Motor Cell.
• Reduced rejection from 15000ppm to 3000ppm by Process improvement.
• Improved VA/NVA ratio from 0.2 to 0.7 in Valuestream Mapping.
• Implemented & sustained Standardized Work Practice for continual improvement.
• Implemented & Sustained Kanban production system in 2 Minifactories.
• Implemented OTED in Turning Centres –4 machines.
• Trained Team leaders on JOB INSTRUCTION METHOD to reduce defects & accidents
Designed systems of Production & Supply Chain department for new manufacturing facility .
• Establish Getrag shaft line around 30 crores business line
• Prepared & Co-Ordinated for Project activities and Updation .
• Prepared layout of Overall Gear manufacturing Plant (See through Layout).
• Co-Ordinated with SCM in Supermarket establishment for 5 Mini Factories.
• Prepared and implemented Milkrun collection system between 8 suppliers.
• Designed & installed Material Handling system.(Raw Material–Finished Goods)
• Introduced Modular type Material Handling Items. (Chutes, Conveyors, Trollies).
• Prepared and implemented image plan (Visualization) of New plant.
TVS Motor Co. Limited, Hosur
Formerly known as TVS Suzuki Ltd., is an Automobile Company manufacturing various ranges of
product from 50cc moped, scooters & Motorcycle up to 150cc
Diploma Trainee June 2000 –June 2003
Roles and Responsibilities
Responsible for coordinating a multi disciplinary teams& suggestion scheme.
Dissemination of JIT, TPM & new Initiatives at shop floor
Implementation of Visualization & Visual control in shop floor
Training & guiding the employees in problem solving methodology
Responsible for coordination project trainees implementation of project.
Formation of new teams/project groups
Dissemination of TPM & new Initiatives at shop floor
Handling employee grievances regarding improvement activities
Preparation of skill matrix for various platforms of employees
Conducting Training programme for workmen & Executive
Responsible for coordinating a multi disciplinary teams& suggestion scheme
Achievements
• Core team member in TPM Implementation in Lakshmi Auto Engine Components Division.(LAC)
• Implemented Jishu Hozen (JH) activities in more than 90 mlc are up to step 4 levels.
• Certification of workmen on TPM activities

5. • Training modules prepared for step 4 JH activities.
• Over all Equipment Effectiveness (OEE) improvement of > 85% for 16 cells (Around 40 mlc’s).
• More than 50 Kaizens done for the reduction of 16 Major Losses.
• Achieved Cost savings of more then 2.5 crores through with KK , JH pillar
• One of the CFT Member in the deming prize (Deming - one of the most coveted awards for TQM
implementation given by JUSE, Japan)
• Cascade training for TQM & TPM programme
• Suggestion in flow raised from 3 per employee in 1998-99 to 41 per employee in 2002-2003
• Active participants implementation of TPM Concepts
• Analyzing customer complaints through Q7 Tools, Good bad analysis & eliminated in Genba
PROFESSIONAL DEVELOPMENT
Training Programmes / Courses Attended in TVS Motor Company
• Undergone course in Auto CAD 2000
• Undergone training programme in JIT BY HIRANOSAN
• Undergone training programme in TQM by WASIOSAN
• Undergone training programme in Inventory management by SISI
• Undergone training programme in Supervisory Development Program
• Under gone training programme in Train the trainer Programme organized by Unique Consultant
• Under gone training programme in Instructional design technology programme organized By
National institute of sales.(NIS)
• Attended Various quality tools Techniques programmelike SPC,QC story, QCTools etc,
• CNC Programming & Operations - GTTC, and CMTC LTD, Bangalore.
• TPM Programmes at various level Conducted by( Yamaguchi san’s – JIPM)
External Conferences
• 3rd
to 5th
/ 8th TPM –JIPMS National conferences organized by CII
• TQM Mission organized by CII, southern chapter
• Kaizen conferences organized by JIPMS
• Rail technologies-Brake system conferences attended in Paris
Training Programmes / Courses Attended in HI TECH GEARS LTD.,
• Lean Manufacturing (Inhouse) ~ Lean Enterprise , USA – Mr.Bill Constatino.
• Adventure in Attitude (Inhouse) ~ NIS Sparta
• Statistical tools & Techniques(FMEA,PFMEA,SQC) ~(Inhouse)~Narayana (MICO BOSCH)
• TPM training for KK & QA Pillar seminar organized by CII.
Training Programmes / Courses Attended in Faiveley transport Rail Technologies.,
• Certified internal auditor for IRIS – System.
• Metro Rail Brake system programme attended in Europe various country.(France, Germany, Italy,
Spain)
• Certification course on “Workshop on Lean Manufacturing” conducted by Faiveley
Management –Eurpoe.
• Certifitied for Lean Implementer course through Lean Institute

6. Page 5 of 5
• Failure Mode Effect Analysis
• Technical training attended in Europe – Delhi Metro, Chennai metro projects ( Compressor, Brake
panel system, Bogie Brakes system, Access and information with Train control system)
COMPUTER SKILLS
• Hands-on-experience in windows 98,2000,XP & presentation packages
SOFT WARE SKILLS.
• Layout simulation
• SAP system.
• Auto Cad 2006
• Visio 2007-VSM
EDUCATION
Bachelor of Technology -Mechnaical Engineering
Diploma in production & Industrial Engineer
Higher secondary Tamilnadu secondary board
STRENGTHS
• Good communication & interpersonal skills
• Self starter and strong believer of hard work
• High energy level
• Excellent team player
• Leadership qualities
PERSONAL DETAILS
Name RAJASEKAR S
Date of birth: Nov 7, 1977
Marital status: Married
Children Male /Female Child.
Languages: English, Tamil, Hindi, Telugu & Kannada
Permanent Address :G4, Classic Homes Matham Road , Hosur
Cell Number :9486593321
Passport number :H7567185
Present salary CTC : 13.5 Lacs /Annum
Excepted salary Negotiable
REFERENCES
Mr. Srinivasan K Mr. K.Rajasekaran Mr. Joseph Abraham
Vice President -TPM Vice President Sr. General manager - SQA
Hi-Tech Gears LTD., Trusted Aerospace Engineering Ltd . TVS Motor Company Ltd.
Mobile No: 09971783869 Ph.no: 9900512421 Mobile :9600822110

7. Page 5 of 5
• Failure Mode Effect Analysis
• Technical training attended in Europe – Delhi Metro, Chennai metro projects ( Compressor, Brake
panel system, Bogie Brakes system, Access and information with Train control system)
COMPUTER SKILLS
• Hands-on-experience in windows 98,2000,XP & presentation packages
SOFT WARE SKILLS.
• Layout simulation
• SAP system.
• Auto Cad 2006
• Visio 2007-VSM
EDUCATION
Bachelor of Technology -Mechnaical Engineering
Diploma in production & Industrial Engineer
Higher secondary Tamilnadu secondary board
STRENGTHS
• Good communication & interpersonal skills
• Self starter and strong believer of hard work
• High energy level
• Excellent team player
• Leadership qualities
PERSONAL DETAILS
Name RAJASEKAR S
Date of birth: Nov 7, 1977
Marital status: Married
Children Male /Female Child.
Languages: English, Tamil, Hindi, Telugu & Kannada
Permanent Address :G4, Classic Homes Matham Road , Hosur
Cell Number :9486593321
Passport number :H7567185
Present salary CTC : 13.5 Lacs /Annum
Excepted salary Negotiable
REFERENCES
Mr. Srinivasan K Mr. K.Rajasekaran Mr. Joseph Abraham
Vice President -TPM Vice President Sr. General manager - SQA
Hi-Tech Gears LTD., Trusted Aerospace Engineering Ltd . TVS Motor Company Ltd.
Mobile No: 09971783869 Ph.no: 9900512421 Mobile :9600822110