T Shanmuganathan
18C,Bagath Singh Street,
NGO Nagar
Kanchipuram.
PIN: 631501
TN, INDIA
E mail ID:ktsnathans_01@rediffmail.com
Mob: +91950000 9850
OBJECTIVE
Seeking assignments in Production,Quality in a growth oriented organization.
SUMMARY OF SKILLS & EXPERIENCE
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A DME Graduate with over 12 years of experience in Production & Quality departments at
automobile part manufacturing sector.
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Extensive experience in production, Quality and to lead a team of people towards achieving the
organization goals with best utilization of the given resources of 4 M’s.
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Able to identify muda’s in process and eliminate by implementing kaizens.
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Hands on experience in maintaining Internal PPM, Customer PPM, complaint levels and ensuring
100% delivery performance.
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Direct involvement in ISO14001, OSHAS18001, TS 16949 documentation and implementation.
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Experience as MR for TS16949, ISO 9001 systems & coordinator for ISO 14001 system.
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Excellent communication skills with troubleshooting, analytical and problem solving capabilities.
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Proficient in developing new products along with the Engineering and quality team to meet the
customer standards.
EDUCATION
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Diploma in Mechanical Engineering from Murugappa Polytechnic College, Avadi, Chennai in
April-2000(Secured 86%)
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Presently pursuing Bachelor Degree in Industrial Engineering from Indian Institute of Industrial
Engineering – Mumbai
PROFESSIONAL EXPERIENCE
ASHLEY ALTEAMS INDIA LIMITED (AAIL), Cheyyar (Near Kanchipuram).
Ashley Alteams is a 50:50 JV between automobile major Ashok Leyland, India & aluminum castings
pioneer Alteams, Finland.
AAIL caters High Pressure Die Casted, Machined & Assembled Products to both automotive &
telecom customers like Ashok Leyland, Volvo, Tata Cummins, Piaggio, Nokia-Siemens Networks ,
Ericsson, etc.
AAIL is accredited with ISO/TS1949:2009, ISO 9001:2008 & ISO14001.
From Feb 2011 to till date working as Manager- Production, heading the diecasting department.
From May 2008 to Feb 2011 worked as Manager – Quality Assurance, QMS & MR
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Responsibilities handled As Head-Die-casting Production
Effective production planning & achievement as per business plan.
On time delivery to in-house machine shop & customers.
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Achieve targeted OEE by effective co-ordination & liaison with Machine Maintenance, Die
Maintenance, PED, Quality departments.
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Preparation of yearly consumables (Revex) & Capex budget.
Monitoring , Control & Reduction of operating & consumable cost.
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Process optimization & productivity improvement.
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Monitor, Control, Review & Reduction of in-house & customer rejections.
Sustenance of TS 16949 & ISO 14001 systems.
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Maintenance of good 5S.
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Motivate personnel for participation in TEI activities like suggestions scheme, Kaizen, QC
Circles & ensure their morale is sustained positively.
Achievements:
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Reduced overall in-house rejections from 15% to 7.2%.
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Increased productivity of part GBH (14.5kg) from 21 to 28 per hour by means of process element
wise cycle time reduction. This resulted in capacity enhancement of 2000T diecasting machine
by 33% & increased sales opportunity for 99.8 Mn INR per annum.
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Developed a system for cost monitoring.
Reduced the LPG consumption cost in melting by 23% resulting in annual saving of 7.3 Mn INR.
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Reduced the die lubricant consumption cost in diecasting by 40% resulting in annual saving of
3.9 Mn INR.
Reduced the norms for major consumables like LPG, Dielubricant, fettling consumables.
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Consistently meeting the challenging targets for diecasting operating cost.
Within short span de-bottlenecked process constraints in 3parts resulting in delivery
improvement from 60% to 100%.
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Effectively liaised with service departments & productionized 3 fully automatic diecasting cells.
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Responsibilities handled As Head-QA
Management Representative (MR) for QMS.
Selection, planning & implementation of inspection systems for all products.
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Co-ordinate with NPD & Engg team on successful customer approval for new products
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Approve PPAP documents & PSW signoff
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Team Leader for SAP QA module
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Overall responsibility for adherence of calibration schedule(Internal & external)
Ensure effective implementation of QMS & Monitor system performance of the organization,
System performance Report to top mgmt through MRM
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Responsible for planning & executing IQA, Process/Product audit, Dock audit, Layout
inspection.
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Selection of certifying body’s & co-ordination for certification.
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Co-ordinate for TEI activities like suggestions, kaizens, QC circles.
Achievements:
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Established QA function & complete inspection setup with necessary facilities like 3D CMM,
Spectro Analyzer, X-Ray Real time radiography, being a foundation member of the green field
project.
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Played vital role in establishing companywide QMS system.
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Successfully got customer approval for all newly developed products.
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Achieved zero customer rejection on newly developed heavy part to Ashok Leyland.
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Effective coordination resulted in successful fresh accreditation of TS 16949 & ISO 9001 Letter
of Conformance for interim manufacturing site & scope, as per timing plan.
Successful achievement of fresh certification accreditation of TS 16949 & ISO 9001 systems to
permanent manufacturing site & scope, as per timing plan.
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Successful closure of initial customer quality problems & gained confidence on AAIL product
quality.
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Maintaining good rapport & relationship with customers, suppliers.
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Nominated by management for machine tool inspection at Italy.
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Selected by management for training at Alteams, China & played key role in technology transfer.
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Successfully implemented suggestions scheme companywide.
Since October 2007 to April 2008 worked as Asst Manager – Production, in KYUNGSHIN
INDUSTRIAL MOTHERSON LIMITED (KIML), Sriperumpudur.
KIML is 50:50 Joint Venture between Motherson Sumi Systems Ltd, India & Kyungshin Industrial
Corporation, Korea.
KIML is the single source supplier of complete wiring harnesses to Hyundai Motor India Ltd.
Accredited with ISO 9002, TS16949, ISO 14001 Certifications & 5 Star award from HMIL.
Key Responsibilities:
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Sectional Head for Wiring Harness ASSEMBLY Section.
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Scheduling, Planning, Organizing and Achieving the Production Targets.
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Responsible for effective utilization of man power.
Responsible for line efficiency, productivity improvements.
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Cycle time Reduction, Line balancing, defect control & reduction.
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Maintain and reduction of Internal & Customer PPM, Zero Customer Complaints.
Maintain 100% service level to Customer.
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Maintain & Ensure good 3C & 5S at shop floor.
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Documentation for TS 16949 / ISO 14001.
From November 2005 to March 2007 worked as Senior Engineer – Production & from
April2007 to October 2007 promoted as Asst Manager-Production, in TI Metal
Forming(TIMF), Chennai.
TIMF, Unit of Tube Investments of India Ltd., MURUGAPPA Group is in manufacture and
supply of Value added metal formed components such as Doorframes, Divisional channels
Components to Hyundai Motor India Ltd., General Motors Ltd and Maruthi Udyog Ltd.
Key Responsibilities :
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Incharge for Hyundai Door frame assembly Section.(Assembly - Bending the section, TIG/MIG
welding & Finishing with manual grinding)
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Scheduling, Planning, Organizing and Achieving the Production Targets.
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Optimizing the process flow and eliminating the NVA activities.
Responsible for line efficiency, Rejection & Rework Control.
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Active co-ordination & participation with quality dept in solving customer end problems.
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Co-ordination with Machine & Tool maintenance depts. to develop corrective & preventive
actions for eliminating/reducing breakdowns.
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Responsible for cost control & cost reduction in consumables.
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Responsible for System development and Implementation.
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Involve and Develop the Teamwork among the people to achieve the organization goals and
policies.
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Active Participation in QC circles, CFT’s.
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Documentation and being auditee for TS16949 / ISO 14001 audits.
Internal auditor for TS16949 / 5S audits
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Conducting awareness training to operators on Product/Process/System/SHE/5S.
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Maintain & Ensure good 5S at shop floor.
Achievements:
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Improved Santro door frame productivity from 360 sets to 400 sets through line balancing.
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Improved LGT (Line Go Through) from 60% to 85%.
Maintained internal process rejections and customer rejections (315 ppm) well within the norms.
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Controlled & reduced welding consumables cost / consumption within the norms.
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Successfully achieved TS 16949 re-certification, being auditee of the department.
Improved 5S audit score from 30 to 65 marks.
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Initiated MIS for machine utilization.
From July 2000 to October 2005 worked as Team Leader – Production in Sundaram Clayton
Ltd. (SCL), Hosur.
SCL, a TVS Group of company, accredited with QS 9000 and ISO 14001 & Deming
Certified company, manufacturer of High Pressure and Low Pressure Die castings for major Customers
like TVS Motor Company, Hyundai, Tata Cummins and Volvo.
Key Responsibilities:
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Worked as Team leader – Production, guiding a group of 6 group leaders (Engineers) &
responsible for delivery and quality of castings to TVS Motor Company, Hosur module.
Production requirement planning based on daily, weekly, monthly customer requirement plan.
Involved in proving of new line and establishing the production.
Controlling of process rejections.
Optimization and improvements in Production, Quality, Cost
Coordinating with warehouse for dispatch of castings, so as to achieve 100% service level.
Worked as core member in ISO14001 & OHSAS 18001 fresh certification audits.
Being an active facilitator in Quality Control circles (QCC).
As a part of the continuous improvement process,
a) Facilitate the employees for making the Kaizens, Jishu Hozens and be a guide for Suggestions.
b) Carryout TPM activities in machines.
c) Being an Active Member in Cross-Functional Team (CFT) for New Die proving & Process
Optimization, rejection elimination/reduction.
d) Being an Active Member in Supervisory Improvement Team Projects for Cycle Time
Reduction, Productivity Improvement Projects.
Task Force & Kaizen Approach for Critical Problem Solving in Foundry Field.
Trainer for TPM, 5S, Safety, EHS system, Casting defects and remedies to operators &
Executives.
Achievements:
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Increased Productivity from 30/hour to 40/hr in a transmission case component (Part wt 4.2kg)
of Hyundai motors by introducing die spray automation and optimizing process parameters.
Increased productivity from 40/hour to 50/hour in 660T M/c’s by optimizing Auto ladle program.
Eliminated a major customer complaint, drilling operation missing in CCL Victor casting.
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SMED Die change over time reduced from 150 min to 60 min in 1350T Ital presse machine and
from 60 mins to 30 mins in 660T machines by implementing SMED techniques.
Eliminated a buffing operation (sub-contract operation) by improving die cooling in Victor model
Cover clutch thereby saving Rs 10 lacs PA.
Improved yield of a Star model component from 40% to 85% by optimizing die and machine
parameters and increased delivery from 1000no.s avg per day to 1800no.s avg per day.
Reduced Victor Crank case rejection from 16% to 5% by working as a full time member in CFT.
Reduced wastage of Aluminum from dross, thereby saving Rs.5Lacs PA
Reduced consumption of die coat and thereby reduced cost of production (Stores & Tools cost).
Maintained Stores & Tools cost of production well within the norms.
Improved Operator safety in PDC Machines and eliminated accidents.
Worked as a core member in ISO 14001 fresh audit in 2001 and ISO 14001:2004 recertification
audit and successfully achieved the ISO certification with Zero NCR.
As a faculty conducted seminars and training sessions on various subjects like TPM, Die casting
defects and remedies, ISO 14001, 5S, Safety etc for both executives as well as Operators.
Solved several operation/quality related problems by functioning as an active member in CFT
and SIT.
IT SKILLS
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MS Office
SAP
ORACLE ERP
AutoCAD
TRAINING PROGRAMMES
Undergone wide range of training on
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Casting Defects & Remedies at ALUCAST, Pune.
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Poka Yoke Training Conducted by TVS motor company Ltd.
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QS 9000 Conducted by Sundaram Clayton Ltd.
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Die gating design training Conducted by NADCA faculty.
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ISO – 14001 Training by Tata Energy Research Institute – (TERI)
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ISO – 14001 Internal Auditor training programme.
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OSHAS 18001
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TS 16949 Awareness & Internal Auditor training programme.
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ERP training in SAP, ORACLE.
STRENGTHS
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Hard and Team working
Good communication & Interpersonal skills.
Self-starter & Self motivator.
Enthusiastic
Ability to learn things quickly
Good presentation skills
OTHER EXPERIENCES
As a part of my diploma course undergone in-plant training at,
1. Brakes India Limited, PADI, Chennai - 50
From July’96 – Dec’96, worked as Trainee in Press shop Department.
2. Carborundum universal Limited, Thiruvottiyur, Chennai
From Jan’98– June’98, worked as Trainee in Maintenance Department.
3. Tata Consultancy Services, Chennai
From Dec’99 – Mar’00, worked as design engineer.
PERSONAL DETAILS
Date of Birth
:
January 19, 1979
Marital Status
:
Married.
Languages
:
Tamil, English
Hobbies
:
-Reading
-Listening and playing music
-Playing Shuttle
-Cycling
-Pranic Healing
Passport No
:
F 8970561
Current Salary
:
Rs.7 lakhs PA
Expected CTC
:
Negotiable
Expected Designation:
Negotiable
Current Location
:
Chennai
Notice Period
:
3 Months.
The above said information’s are true and correct to the best of my Knowledge.
(T SHANMUGANATHAN)