M. KARTHIKEYAN
Operating Engineer
Chennai
Summary
Dynamic Operating Engineer with over 12+ years of expertise in tire manufacturing, driving significant improvements in operational efficiency and product quality. Proficient in implementing advanced methodologies such as TPM, Kaizen, and Lean Manufacturing, resulting in substantial waste reduction and cost savings. Skilled in integrating IIoT technologies to enhance real-time monitoring and decision-making processes, ensuring compliance with stringent safety and quality standards. Committed to fostering a culture of continuous improvement and innovation, contributing to enhanced manufacturing performance and customer satisfaction.
Overview
13
13
years of professional experience
7
7
years of post-secondary education
5
5
Certifications
Work History
Operating Engineer
JK Tyre & Industries Ltd
05.2012 - Current
- Optimized processes across Extrusion, Calendaring, and Electron Beam Radiation for a 15% rise in OEE.
- Managed end-to-end Production Planning, Quality Assurance, and Cost Optimization, achieving a 30% reduction in waste
- Adopted TPM, Kaizen, and 5S methods to ensure zero major safety incidents across five years.
- Designed and introduced Skill Matrix-based training for operators, leading to a 20% increase in workforce efficiency.
- Integrated IIoT-based real-time monitoring, accelerating decision-making speed by 15% and reducing defect detection time
- Conducted HIRA audits and ensured 100% compliance with ISO and British Safety Council safety standards
- Enhanced tread compound uniformity, minimizing material waste and improving tyre performance & durability
- Led cost-saving initiatives, trimming annual production expenses through raw material and process optimization
- Collaborated with cross-functional teams to implement predictive maintenance, cutting unexpected downtime by 30%
- Strengthened quality control measures, resulting in a 20% drop in customer complaints related to tyre defects
- Established Standard Operating Procedures (SOPs) for new product trials, reducing trial time by 40%
- Spearheaded an energy reduction initiative, lowering electricity usage by 10% in production lines
Education
B.E. - Electronics & Instrumentation
Anna University
Chennai 02.2016 - 05.2020
Diploma - Electrical & Electronics Engineering
Thiyagarajar Polytechnic College
Salem 06.2009 - 05.2012
Skills
Extrusion & Calendaring
EPS System
7 Steps Problem Solving Methodology
Rupper Process
Leadership
Deming Cycle (P-D-C-A)
Process Optimization
OEE Enhancement
TPM
5S
Kaizen
PQCDSME
Lean Manufacturing
ISO Compliance
HIRA
British Safety Council
Poka-Yoke
7QC Tools
X-R Chart Analysis
First Piece Inspection
Startup Checks
Predictive & Preventive Maintenance
KPI Management
FIFO
P2P Process
IIoT Implementation
Ms Office
Smart MES Integration
Real-Time Monitoring
Waste Reduction
Inventory Management
Scrap Handling
Master Control Plan
Skill Matrix Development
Key Performance Indicators (KPIs)
Training & Skill Enhancement
7C Communication
Negotiation
Root Cause Analysis
Time Management
Risk Assessment
Firefighting & First Aid Training
PPE Management
Workplace Safety Audits
Certification
Leadership Development Program.
Accomplishments
- Enhanced Simplex Extruder OEE from 75% to 90% via TPM & Kaizen implementation.
- Reduced Duplex Extruder rework rate by 45% (5.71% → 3.14%) through Poka-Yoke.
- Optimized Quadruplex Extruder productivity by 20% through workflow reengineering.
- Minimized tread weight & length variation rework by 30% in Duplex Extruder.
Additional Information
- Current CTC: Rs. 7 LPA,
- Notice Period: 3 Months.
Disclaimer
I hereby declare that the information provided above is true to the best of my knowledge.
Timeline
B.E. - Electronics & Instrumentation
Anna University
02.2016 - 05.2020
Operating Engineer
JK Tyre & Industries Ltd
05.2012 - Current
Diploma - Electrical & Electronics Engineering
Thiyagarajar Polytechnic College
06.2009 - 05.2012