Kaleeswaran Annamalai
Head R&D
Chennai,TN
Summary
Wish to handle a challenging role, where I can ensure to utilize my domain knowledge (“Plastic Engineering and testing” particularly in Polyurethane), having wide experience in Plastic Production, processing & development, technical service & Marketing with inherent skills and exposure in new application developments and customer supports. I am ready to contribute my level best to the company’s success and growth as an individual and Team.
Detail-oriented individual with exceptional communication and project management skills. Proven ability to handle multiple tasks effectively and efficiently in fast-paced environments. Recognized for taking a proactive approach to identifying and addressing issues, with a focus on optimizing processes and supporting team objectives.
Demonstrates strong analytical, communication, and teamwork skills, with proven ability to quickly adapt to new environments. Eager to contribute to team success and further develop professional skills. Brings positive attitude and commitment to continuous learning and growth.
Overview
23
23
years of professional experience
2
2
years of post-secondary education
Work History
Head R&D
Manali Petrochemicals
Chennai, Tamilnadu
03.2024 - Current
- Head R&D for polyurethane application development
- Handling 15 members team for product developments, batch clearance & trouble shooting
- Handling automotive, furniture, footwear & Integral skin systems
- Self-motivated, with a strong sense of personal responsibility.
- Worked effectively in fast-paced environments.
- Skilled at working independently and collaboratively in a team environment.
- Proven ability to learn quickly and adapt to new situations.
Manager
BASF INDIA LTD
Navi Mumbai, Maharashtra
03.2017 - 02.2024
- Product development as per customer requirement & Customer trial sample preparation
- Fine tuning trial materials, existing products based on customer inputs
- Recipe management, MOC, PTR and handover of recipes to mfg. plant (Thane)
- Handling raw material trials & testing
- New product development and tool development
- CAPEX handling (Utilized 90% from 2017 onwards)
- Alternate RM validation
- Application lab set up for new development and existing products testing
- Training internal & External (Safety, Production, Process)
- ISO 9001, 14001 & IATF 16949 certification for lab, sales & marketing (Business)
- Coordination & implementation of audit recommendations (Internal, External)
- Documentation for Process Safety.
- Safety reviews are performed together with expert groups.
- Running six sigma projects for marginal improvement in PMU.
- One of the Leading Manufacturer of PU raw material (Polyol, Isocyanate), Care chemicals, Dispersion, TPU and Molded PU parts etc. Customers (Polyurethane Products): Maruti Suzuki, Hyundai, Tata motors, Bajaj, VW, Kia, Honda, Toyota.
Deputy Production Manager
BASF INDIA LTD
Dahej, Gujarat
02.2013 - 02.2017
- Plant established for automotive products production (Bump stopper)
- Established production & process and monitoring
- Handling raw material trials & testing
- New product development and tool development
- Training to all plant personnel (Safety, Production, Process)
- ISO/TS 16949 certification related documents prepared and maintained
- Coordinating & implementation of recommendations received from Customer Audits
- Documentation for Process Safety
- Safety reviews are performed together with expert groups
- Cellasto plant, Dahej. One of the Leading Manufacturer of PU raw material (Polyol, Isocyanate), Care chemicals, Dispersion, TPU and Molded PU parts etc. Customers: Maruti Suzuki, Ford, Hyundai, Tata motors, M & M, Bajaj, Honda.
Senior Production/Process Engineer
TAKATA INDIA PVT LTD
Chennai, Tamilnadu
01.2009 - 01.2013
- PU Plant Established for steering Wheel.
- Familiar with Program Machine & Process Set up.
- New Development Materials CKD – Localization (low cost material - POLYOL, ISO)
- Handling new materials trials & testing (POLYOL, ISO, IMC, Release Agent)
- To meet customer volume of Production Capacity and assembly of steering wheels.
- New product development
- One of the Leading Manufacturer PU Steering Wheels, Seat Belts & Airbags Customers: Honda, Nissan, Daimler, Volvo, Ashok Leyland, Tata.
Production Engineer
SECO KOMOS INDIA PVT LTD
Chennai, Tamilnadu
01.2008 - 01.2009
- Handling production capacity and assembly of steering wheels. Achieving per day 1100 complete Wheels.
- Analysis of root cause on rejections. Reduced the rejection from 3% to 1%.
- Initiating and developed Cost Saving Project. (Removing the non-value add materials and thro’ Saving of 3.6 Mn Rupees per Annum)
- Undergoing new product development.
- Handling manpower allocation.
- Providing functional and quality management training to our team.
- Focusing and implementing Kaizen project, Continuous improvement, 5S etc.
- One of the leading Manufacturer of PU Steering Wheels Customer: Hyundai
Production Engineer
Poly Flex India Pvt Ltd
Chennai, Tamilnadu
01.2007 - 01.2008
- Handling production capacity and focusing product quality.
- Minimizing Rejection thro’ Kaizen Project.
- Identifying Solution for Troubleshooting in the shop floor
- Resource handling. (Allocating Manpower)
- New product development (Conducting New raw material trials, New mould trials)
- Focusing on Cost saving project and looking for lean manufacturing.
- Established and maintaining Contingency plan.
- SIPCOT, Thandalam. One of the leading Manufacturer of PU Automotive Cushions Customer: Hyundai & Ford.
Production Executive
Chem Crown Exports Ltd
Chennai, Tamilnadu
01.2005 - 01.2007
- Establishing Production plan
- Ensuring Shop floor 5S activities
- Establishing and maintaining SOP document.
- Analyzing to improve the machine capacity and conducting trials on alternate material.
- Mould correction and rectification in case of any disorder.
- Sedarapet, Pondicherry. One of leading Manufacturer of PU Shoe Soles Customer: Ponds, MM Shoes, Bata.
Trainee Shift In charge
Alpha Foam Ltd
01.2004 - 01.2004
- In-plant training
- Exposure to machines handling
- Pune (2004) One of leading Manufacturer of PU Automotive Seats Customer: Tata, M & M
Education
Master of Business administration - Sales & Marketing
NIBM
KozhikodeMaster of Business administration - Operation Management
IIBM
DelhiPost Graduate Diploma - Plastic Processing and Testing
Central Institute of Plastics Engineering & Technology
Chennai 01.2023 - 12.2024
Bachlor's of Science - Chemistry
Govt. Arts College
Udumalpet01-2001
Master of Science - Chemistry
Kalinga University
Raipur, India 04.2001 -
Skills
Preferred Knowledge Area: Polyurethane Foam (PU) Production, Process, Product development
Material selection for product development, Recipe management, testing & trials, foam production process, specification set & parameters define for Polyurethane systems, validation of new raw material & alternate raw material, Vendor development for testing facility & 3rd party testing as per customer requirements
MACHINE’S HANDED:
PU Rotary Machine (Low pressure):
Frimo
60 Station NOUVAMA GUSBERTI(Automatic)
18 Station NOUVAMA GUSBERTI(Manual)
40 Station PUMA(Automatic)
PU High pressure machine:
Henneike polyurethane machine (Germany)
Cannon polyurethane machine (Italy)
KM polyurethane machine (Germany)
GMA (Rim polymers, (Singapore)
TOHO Machinery (Japan)
Robot Handling:
Fanuc 2000 iA
ABB
Motoman
Polyurethane Material handled:
BASF, Dow, Euro Sole, Coim, Bayer and Huntsman
Training Program undergone:
Quality Management Systems- ISO 9001 & IATF 16949
Environment management system- ISO 14001
RCMS
Leading & Motivating
Goal Setting
Permit to work system
5S Training
Kaizen and Continuous improvement
OHSAS
Six Sigma
Friendly, positive attitude
Teamwork and collaboration
Customer service
Problem-solving
Flexible and adaptable
Multitasking
Decision-making
Problem resolution
Accomplishments
- Application Development Lab Set up
- Successful set up of application lab for Transportation material validation, trials, customer sample preparation, testing, validation report & New product developments.
- 2Wheeler, 4-wheeler, Railways seating projects handled
- Production plant set up
- Cellasto line dismantle from BAPC, China and installed at Dahej. Achieved 3.4 mio pieces and reduced rejection rate to 1.2%.
- Training provided to shift in-charges and operators
Timeline
Head R&D
Manali Petrochemicals
03.2024 - Current
Post Graduate Diploma - Plastic Processing and Testing
Central Institute of Plastics Engineering & Technology
01.2023 - 12.2024
Manager
BASF INDIA LTD
03.2017 - 02.2024
Deputy Production Manager
BASF INDIA LTD
02.2013 - 02.2017
Senior Production/Process Engineer
TAKATA INDIA PVT LTD
01.2009 - 01.2013
Production Engineer
SECO KOMOS INDIA PVT LTD
01.2008 - 01.2009
Production Engineer
Poly Flex India Pvt Ltd
01.2007 - 01.2008
Production Executive
Chem Crown Exports Ltd
01.2005 - 01.2007
Trainee Shift In charge
Alpha Foam Ltd
01.2004 - 01.2004
Master of Science - Chemistry
Kalinga University
04.2001 -
Master of Business administration - Operation Management
IIBM
Master of Business administration - Sales & Marketing
NIBM
Bachlor's of Science - Chemistry
Govt. Arts College
PROFILE
- Design and optimize PU systems (flexible, integral & footwear)
- Work with marketing teams to align product features with customer needs.
- Provide technical support to customers
- Select appropriate polyols, isocyanates, and additives for performance targets.
Declaration
I hereby declare that the information provided is true to the best of my knowledge and belief.
A.Kaleeswaran
Manager - Application Development