M. Muthumariappan

Dynamic manager with 19+ years of extensive experience in Paintshop Production, quality control and process optimization at Rockman Industries Ltd. Demonstrated success in team leadership and inventory management, resulting in enhanced operational efficiency. Focused on achieving results through strategic initiatives and promoting a culture of safety compliance.

• Production planning as per customer requirements on a daily basis in coordination with various departments and completing the plan as per the target
• Prepare yearly budget planning and control all the parameters within the AOP budget
• Capacity calculation and manpower calculation through processing time
• Manpower handling, job allocation, training and development of subordinates, and continuously improving their skills by setting up a DOJO room in the paint shop to avoid dependency
• Coordinate with the maintenance department, follow the booth cleaning activities, and all PM activities, and reduce paint shop MTTR and MTBF
• Lead for the Paint CFT and reduce paint consumption, energy consumption, direct material optimization, and resource management
• Optimize the process and implement the flow manufacturing in alloy wheel painting
• Process a feasibility study of new products with the new product development (NPD) team
• Ensured a safe work environment by tracking and investigating the workplace, promoting a safety culture

• Increase the alloy wheel production capacity from 4,500 units to 9,000 units per day by installing one transporter conveyor and running powder coating and liquid painting in parallel
• Increase Paintshop EBITDA from 5% to 15%
• Increase the paint transfer efficiency from 60% to 80%
• Spearheaded the robot line process and increased the pass ratio from 83% to 90%, and improved the productivity by designing the hangers, thereby increasing the paint shop capacity from 650 vehicles to 800 vehicles for the year 2018
• Solely responsible for introducing the photo sensor and camera system in the robot line, which resulted in eliminating manual edits and robot BELL damage, thereby resulting in cost savings of close to INR 20 lakhs
• Erection and commissioning of the robot line in Vallam Plant 2 with the DURR Engineers team and successfully launched six-axis IRB 5500 model robot line, coordinating with the ABB team
• PTCED capacity increased from 1,250 to 1,380 vehicles per day by modifying the frame with Toolbox and child parts

• Father's Name: Mr. Mottaiasamy
• Date of Birth: 11/07/85
• Gender: Male
• Nationality: Indian
• Marital Status: Married
• Religion: Hindu

• Paint shop operations management (pretreatment, ED, powder coating, robot painting, plastic painting)
• Process optimization and continuous improvement (Kaizen, Lean, TPM)
• Quality Management Systems (IATF 16949, ISO 9001)
• IoT system implementation in paintshop
• Increase Paintshop EBITDA
• PPAP, FMEA, Control Plan, and SPC implementation
• Transfer efficiency improvement and paint material cost reduction reduce sludge generation
• Equipment maintenance coordination and downtime reduction
• Inventory management

• Be a mentor and achieve the platinum award in CII National level Kaizen competition in 2024.
• Achieve the Jury champion award in CII National level Kaizen competition in 2024.
• Achieve 3 Golden award & 2 Silver award in Internal Group level Kaizen Competition.
• Achieve Best performance Award for achieve Highest Cost saving of 1 Crore 59 Lakhs in FY 2023 -24.
• Achieve trial blazer award for the year 2018 for the highest ever rolled out of 1024 vehicles in a day which is the highest ever as on date in RE Plant1.
• Achieve trial blazer award for the year 2021 by Eliminating 5th Gun in powder coating process and reduce the powder wastage from 25% to 15% per day and resulting in cost saving of about INR 15 lakhs annum.

• Advanced FMEA & the changes, Process FMEA with IATF 16949 linkages.
• IMS Audit training ISO 9001-2015, ISO 14001, ISO 45001.
• Introduction to Auditing Techniques as per 19011.
• Communication Excellence programmed.
• Act, don’t react (Competency – Sense of Urgency).