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 , IndustrializationCapex Management , Capacity management of Mult location Operation, Quality Management, Projects and Process optimisationExpertise in Lean Manufacturing, Operations Excellence, Value Stream Mapping, Team Management , Human resource development and Cost ManagementStrong hands on experience in Process Improvement, New program development & Operational excellence Projects through Lean Methodologies and exposure in process development through Industry 40 (“IOT”)Actively involved in establishing Business Excellence (Organizational Performance Excellence) and Quality Management practicesStrong hands on Leading CFT and Coordinating with Cross functional heads to achieve the milestones as per the Targets
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