R. SURESH
SENIOR MANAGEMENT PROFESSIONAL – MANUFACTURING EXCELLENCE, PLANT OPERATIONS, PROJECT MANAGEMENT
[email protected] +91-9890622504 / +91-8901881504 https://in.linkedin.com/in/suresh-rajendran732795117
Key Skills Lean Manufacturing
Targeting leadership assignments in Manufacturing, Plant Operations
Plant Engineering, Manufacturing, Shop Floor Operational Excellence
Profile Summary
Greenfield Projects, Plant Set-up Machine Selection, Line Set-up, Shop Floor Layout Production Planning & Control Plant & Utilities Maintenance New Product & Part Development Quality Management Systems (ISO 9000, TS 16949, ISO 14001, Lean, 5S, TPM, TQM, Kaizen, Poke Yoke) Cycle Time Reduction, Wastage Reduction, Capacity Study, Line Balancing & Improvement
Nearly 18 years with impressive success in heading operations of CNC Machine Shop consisting of 120+ machines (HMC,VMC, CNC & SPM) including Cylinder Block, Cylinder Head, Crankcases, Transmission cases, Clutch Housing and Auto Parts Highly skilled in setting-up state-of-the-art & commissioning Manufacturing Systems (Rs. 100 Crores CAPEX), Greenfield & Brownfield plants Excellent track record of setting-up of plants from scratch and turning around performance of underperforming production units into high performing units by devising suitable strategies Proven skills in managing technically advanced, cost-efficient and state-ofthe-art production systems Expertise in developing techniques for maximizing utilization of manpower / machinery and enhancing productivity Delivered competitive advantage by enhancing operational effectiveness of plants, maximizing plant profits, driving process transformations & cost savings, uncovering underlying issues at plant level and reducing wastage Strong exposure in programming of CNC machinery such as Makino a51, a71, a81, Daewoo HM630, BFW and various types of VMC Sound knowledge of AutoCAD 2015 Dynamic, flexible & approachable People Manager with strong interpersonal, analytical, problem solving skills
Career Timeline Aqua Sub Engineering as CNC Programmer
2000-2002
Craftsman Automation as Manager Manufacturing - CNC Machine Shop
Craftsman Automation as Assistant Manager
2002-2004
G -Plast as Senior Engineer
2004-2009
2009-2010
Continental Engines as Deputy Manager Manufacturing
2010-2016
Since 2016
OMP India as General Manager (Role: BU Head Machine Shop)
Education
1999: Diploma in Mechanical Engineering from N.L. Polytechnic, Coimbatore, Tamil Nadu
Work Experience Since Nov’2016
OMP India Private Limited, Baghola, Palwal as General Manager (Role: Business Unit Head - Machine Shop Operations) Responsibilities: Spearheading end-to-end operations of Machine Shop (consisting of CNC, VMC, HMC, ID Broach Machines, Face Broach Machines, Induction Hardening Machine, CNC Grinding Machines) including PPC, Maintenance, Quality Control, Process Improvement and Manpower Management Facilitating achievement of monthly production target of 45000 numbers, supported by a team of 220+ Preparing and implementing production plans; planning & prioritizing daily workload to achieve productivity standards & goals Ensuring that all products are manufactured at the best acceptable standards possible; working to maximize productivity while adhering to safety policies and laws Planning, controlling & troubleshooting quality issues; achieving zero breakdowns, zero accident & zero customer complaint Tracking all supplies and maintaining inventory for smooth operations Monitoring quality; improving processes through Lean & TPM Reviewing workers’ performance and daily activities to ensure time, quality, zero defects and timely production; providing timely and ongoing feedback on performance-related matters to encourage excellent performance
Mar’2010 – Oct’2016
Craftsman Automation Pvt. Ltd., Pune Plant - 3 as Manager Manufacturing (HOD) - CNC Machine Shop
Key Achievements: Set-up 2 new plants; led projects worth Rs. 80 Crores and 96 Crores in Pune Slashed cost by 20% by replacing high-end machinery with low-end machinery Developed a team of 3 Supervisors in Asst. Manager cadre and 12 Operators in supervisor cadre Reduced cost by Rs. 8 Lakh / month by improving tool life and introducing coolant mgmt. & tool life monitoring system Decreased cycle time of critical machinery by reducing air cut time, indexing time & by using a combination of tools
Highlights: Headed operations of CNC Machine Shop with 120+ machinery (HMC, VMC, CNC & SPM) including Single & Multi Cylinder Heads, Crankcases, Cylinder Blocks, Transmission Case, Clutch Housing, Auto Components Successfully dealt with high profile customers such as M&M, Tata Cummins, John Deere, Volvo Eicher, AV Tec, Tafe Motors, Mahindra Navistar, New Holland, JCB, Tata Motors, Caterpillar, Daimler, so on Consistently achieved set targets for quality, cost & delivery; implemented counter-measures to achieve MIS parameters through PDCA cycle Decreased cycle time through modification in machinery thereby increasing production across all cells by 20% Managed procurement of various Jigs, Fixtures & Spares Increased productivity by 15% by implementing automation concepts like Gantry, Robo, Auto Conveyors & Auto Gauging Created design of Workstation and Process Layout; optimized the flow of process through modification in the existing layout Reduced conversion cost per unit by modifying equipment, process flow, working practices and consumables Ensured smooth flow of operations through Kaizen, 5S and Poke Yoke Modified new tools; controlled stocks of tools & inserts by coordinating with Central Tool Grip Dept.; reduced CPC through cutting tools trial Coordinated product development customization functions; conducted inspection & trials; approved new SPM (Special Purpose Machines) at suppliers’ end; approved hydraulic fixtures at supplier’s end Identified idle times of manpower through Most Study Successfully established the Machine Shop from scratch involving shop floor layout and erection of machinery Played a vital role in: o Decreasing production cost through business process re-engineering, manpower re-allocation and optimum utilization of machinery o Reducing cycle time by monitoring hourly production, troubleshooting, proper line balancing and placing correct people to correct position
May’2009 - Feb’2010
Continental Engines Ltd., Bhiwadi as Deputy Manager - Manufacturing
Aug'2004 - Mar'2009
Craftsman Automation Pvt. Ltd., Pithampur as Assistant Manager Assignments Handled: Aug'2004 - Dec'2005: Non-Standard Line Dec'2005 - Apr'2007: GMI Cylinder Head Line Dec'2005 - Apr'2007: GMI Cylinder Block Line May'2007 - Mar'2009: DI Block Line May'2007 - Mar'2009: Eagle BD Plate Line & Eagle Block Line
Key Achievements: Consistently achieved daily production target of 120 in Eagle Block & Bedplate Line Successfully increased production to 180 per day Minimized manpower requirement in Eagle Line from 36 to 28 persons and DI Block Line from 30 to 24 persons Decreased cycle time in bottle neck operations by changing fixtures, tools and process
Highlights: Successfully developed the following: o Eagle Gasoline Block o SPM, Air Leak & Continuity Test and Washing Machine Approval o W201 Block (M&M) o W201 Bed Plate (M&M) o W408 Block (M&M) o 4DI & 3DI Cylinder Head (M&M FES) Drove complete operations of Machine Shop (CNC, VMC, HMC and SPM) supported by a team of 9 Engineers & 75 Operators Ensured adherence to budget; analyzed & resolved in-process quality issues and reduced customer complaints from 8/year to 3/year Introduced statistical process control techniques Reduced rejection to 4000 from 12000 ppm Implemented 5S in entire shop floor Introduced Line Conveyor system for easy material storage Increased production in: o 3Di Block Line from 160 nos. to 220 nos. per day o 4Di Block Line from 140 nos. to 180 nos. per day Implemented functional gauges for inspection thus saving time
Previous Experience Mar’2002 – Jul’2004
G-Plast Pvt. Ltd., Coimbatore as Senior Engineer
Jan’2000 – Jan’2002
Aqua Sub Engineering, Coimbatore as CNC Programmer
May’1999 – Dec’1999
Dhamodar Engineering, Coimbatore as Supervisor
Personal Details
Date of Birth: 11th June 1981 Current Address: Flat No. 114, A Wing, Oxy Ultima Society, Kesananad Road, Wagholi, Pune - 412207 Permanent Address: 41A, Sowdamman Kovil Street, Moolathurai, Illuppa Palayam (P.O.), Sirumugai (Via), Coimbatore - 641302, Tamil Nadu Languages Known: Tamil, English, Telugu, Kannada and Hindi
