K. MANICKARAJA
Mechanical Engineer
Kancheepuram
Summary
PROFILE SUMMARY
Overview
13
13
years of professional experience
4
4
years of post-secondary education
Work History
M/S FAURECIA EMISSION CONTROL TECHNOLOGY PVT LTD
CHENNAI
07.2018 - Current
- Pioneer in Exhaust systems for Passenger Cars , Supplying both catalytic converters and Mufflers for Major OEMs like Hyundai , KIA , FORD , Nissan , PSA
- Yanmar
- Role : Industrial program leader , Capacity manager for India , GBD Process Expert, INDUSTRIAL DEVELOPMENT
- Responsible for the work packages execution for the Industrial Development of the Program at the Plant: industrial footprint, CAPEX definition, Plant equipment selection (new / reuse / share), Plant layout, internal flows, industrial trials
- Capacity Management for all India FCM and identifying CAPEX requirements for upcoming business
- Responsible for the launch planning and budget from definition till execution
- Participate in the development of Make or Buy strategy in accordance with Purchasing, Program and Plant(s)
- Be responsible for HSE and ergonomic convergence in the Plant
- PROCESS DEVELOPMENT
- On behalf of the plant, approval of all upstream Process Development activities (M-BOM, Production Line Definition, Equipment List, Tooling & Equipment Definition & Sourcing from supplier kick off until final acceptance, HSE & Ergonomics)
- Process and Machine Capabilities, line capacity, Direct Labor, PPM, Scrap-rework rate, change over time and on-time delivery
- Designing Process with high robustness to optimize line balance , reducing Skill level and 3Ms
- Optimize the CAPEX through the footprint, capacity analysis and the equipment selection
- Optimize layout and Process flow as per the guidelines of Lean Industrial design
- PRODUCTION LAUNCH
- Management of launch activities (Run at Rate) at the Plant and staffing of the extended support team until the full validation
- Support the production during the ramp-up after the handover to the Plant
- Support Engineering Change Management as necessary
- Report all Industrial Development risk analyses and associated action plans
- Report on Plant launch activities to the Plant
- KEY ACHIEVEMENTS
- Successfully launched three New Programs (Kappa Improvement – KIA motors , Bi3 – Hyundai Motors , Gamma 2 – KIA.Motors) and awarded as Key contributor for the Green Launch
- Achieved Scrap value < 0.22% against sales
- Introduced karakuri between work stations to ease the material handling and to reduce work space
- Launched the program by meeting all key metrices such as cycle time , rework , UPH as per the program assumptions
- Expertise in GBD Canning process and Well excuted in “IOT” Industry 4.0 and implemented traceability system with retention period of 15 years
- Played lead role in VAVE project and resulted with annual savings of 150 lakhs INR / annum through the Yield improvements and localisation projects
- Awarded 1st place in Poka yoke competition across Southern region conduced by ACMA.
Asst. Manager, Engineering Graduate Trainee
M/S WHEELS INDIA LIMITED, TVS
CHENNAI
07.2010 - 07.2018
- Products :Air Suspension Components for Luxury buses,ICVs, Trucks & Trailors , Lift axles and also Wheels for Various ranges of Vehicles from Light Passengers to Earth Mover
- Budget preparation, Capex Proposal creation for Cost Reduction & Business Process Excellence projects
- Responsible for introducing automations , Layout optimisation and improving process capability
- Meeting On time delivery of New products to customer through project planning
- Developing Team members & supervisors to build strong team in New product development for process standardisation & to sustain manufacturing system
- Preparing APQP documents for Prototype models
- Coordinating Lean improvement projects to Control material wastage & meet the expected manufacturing yields
- Part of CFT to close Customer complaint & Internal rejections through proper CAPA
- KEY ACHIEVEMENTS
- Improve customer service & collaboration-First pass yield by 15% & OTD by 30% in air suspension division using Value stream Mapping & Lean
- Compliance on quality – Reduced rework retention time in the system by 50%
- Improve manufacturing capability -OEE 74% achieved from the level of 56% using SMED & Fundamentals of Factory physics
- Implemented Lean culture in manufacturing floor -Visual factory , 5S, through a technique called Self Directed work teams.
Education
B.E - Mechanical Engineering
PSNA Engineering College
08.2006 - 05.2010
Skills
12 years of Rich experience in Process designing, New product development, Project Management, Lean Manufacturing, Manufacturing Strategy, P & L Management , Business plan, VAVE , Industrializationundefined
Additional Information
- EXTRA CURRICULUM , Won Excellence Award in National Level Quality Circle Competition Conducted by QCFI Won Par Excellent Award In Poka-Yoke Competition Conducted By QCFI Won Bronze award ACT SUMMIT-2015 conducted by ACMA. Selected as Unsung Hero by ACT ACMA -2015. Won Third place in Southern Zone level SMED competition conducted by ACMA 2016 Won several competition like Kaizen, SMED, Quality Circle & Case study presentation conducted by QCFI, ACMA. Shortlisted for ACMA 4th Case Study Competition Finals and participated with 4 case studies. Won Platinum Award in Poka Yoke Competition conducted by QCFI. Awarded as best Improvement Idea contributor of the month
Timeline
M/S FAURECIA EMISSION CONTROL TECHNOLOGY PVT LTD
07.2018 - Current
Asst. Manager, Engineering Graduate Trainee
M/S WHEELS INDIA LIMITED, TVS
07.2010 - 07.2018
B.E - Mechanical Engineering
PSNA Engineering College
08.2006 - 05.2010
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