K. Vignesh

Roles and Responsibilities at ALSTOM

• Conducting a design review with system engineers to understand the customer requirements and determine make-or-buy decisions.
• Preparing Project PFMEA and tooling lists
• Preparing Paint Process Qualification (PPQ) Plan and compiling qualification test report
• Finalizing Paint shop layout and preparing RFQ and Calculating method time
• Conducting training for site experts and associates
• Developing a strategic plan for site DPU reduction
• Reviewing site control plan and work instructions
• Providing special process painting training to suppliers
• Performing painting process audit at supplier sites

• Painting expert to qualifying Painters, Grit blasting and Anodizing operators
• Responsible for Process establishment of new products in paint shop and Paint Process Validation
• Quality inspection and confirming compliance to the SSPC standards for Casting parts
• TUV Certified internal auditor and Knowledge in ERP(M3) & SAP
• Equipment's handled to confirm quality of casting surface profile by surface profile gauges and Visual standards of SSPC and NACE
• Monitoring and control of Anodizing plant process parameters

• Delivery of painted chassis and sheet metal parts as per model sequence including NPI and responsible for Paint shop metrics like RFT, NC (Internal and External), Line stoppage and Rejection
• Establishment of new facility equipment’s and proving the process - 2K equipment installation Graco Pro-mix2KS

• TPM Co-Ordinator Paint shop and Active team member in VSME, TQM
• Planning the painting sequence & supporting the main assembly line
• Experience in Surface-Treatment and CED shut down activity
• Scheduling Preventive Maintenance for Surface-Treatment and CED Line
• Monitoring and control of Degreasing and Phosphating process parameters like Total Alkalinity, TA, FA, Gas pointage, Acid ratio (TA/FA)
• Analyzing crystal structure with SEM and P ratio every 2 months once.
• Paint shop operators' skill evaluation and manpower deployment with respect to skill level
• TAFE process audit team member to validate painting process at vendor end
• Six Sigma project team member
• Preparing and maintaining Key Documents of paint shop SOP, PFD, PFMEA and WI
• Implementation of process changes (ECN) in production line by reviewing PFMEA against customer complaints
• Painted quality confirmation as per ASTM Standards through equipment's like WFT, DFT, SST, Spectrophotometer, Wave Scan and Roughness Gauge

• Projects involved in mono coat development for new models at Honda
• Long term and short-term quality test conducting for wet paint and Dry Film as per Honda Engineering Standards
• Production planning and Dispatch Scheduling of Paints, against weekly and Monthly production plan of HMSI
• Rework reduction in Pearl sun beam white from 5% to 2% by changing formulation in thinner
• New shades implementation in motorcycle segment like Maple brown, Lusty red (cocktail shade)
• Shade matching between Robotic and Manual Line by adjusting robot parameters like RPM, Shaping air dual (inner/outer), HV, and Flow
• Calculating Cost per unit for new shades

• Kaizen in paint packing by changing packing size from 1:4 to 1:1
• Troubleshooting the paint defects in Bumper and Body line
• Robot Parameters adjusted to meet the desired DFT and Shade during 90 K to 100 K project experience in TKML
• Wet NVM and Crater Test confirmation for batches
• DFT optimization and Shade matching of body and bumper, through changing process parameters robot, Solvent balancing, and tinting
• Equipment's handled in KNPL Spectrophotometer, Gloss, and Wave scan
• RCA and RCA report in 8D format submission to customer for defects
• Color matching by online tinting with respect to master shade panel

• Hyundai Plant 2 CED line process and product inspection on Daily basis Process ViZ.NVM and Ash, MEQ, pH. Product – DFT, solvent rub test, Cross hatch test, Gloss, Roughness value (Ra)
• Equipment's handled in ED LAB such as GLC, Auto titrator (MEQ), and Muffle Furnace
• Paint F1 & F2 and Solvent addition to CED tank based on bath analysis report
• Handling ACED lines of HMIL vendors and Troubleshooting those lines for defect reduction and process improvements