M. BALA CHANDER
HPDC PRODUCTION (Aluminium Die Casting)
Chennai
Summary
I am an HPDC production professional with over 24 years of experience in aluminum die casting. I have handled complete production operations along with maintenance, PPC, and quality systems. I focus on productivity improvement, rejection reduction, and system-driven management to achieve business targets.”
Overview
25
25
years of professional experience
2012
2012
years of post-secondary education
3
3
Languages
Work History
MANAGER - PRODUCTION
IL GAHNG AUTOMOTIVE INDIA PVT. LTD.
05.2023 - Current
- Manager responsible for monthly production, delivery & quality
- Handling 10 machines such as 1250T , 1650T & 2700T (UBE, & BHULER)
- Process knowledge about Cylinder Block, Transmission case and Clutch Housing parts
- Handling 3 Shift engineers & 75 workmen's
- Defect analysis & action implementation for quality improvement
- Process optimization for new dies
- Process proving at supplier end for outsourced dies
- Production improvements by (70% to 85.5%)
- Rejection reduction from 7% to 2.5% end to end
- Process standards preparation
MANAGER - PRODUCTION
MK TRON AUTOPARTS PVT. LTD.
11.2021 - 05.2023
- Manager responsible for monthly production, delivery & quality
- Handling 19 machines such as 130T & 800Tton (Toshiba, Zitai, LK & Toyo)
- Handling 3 Deputy Manager, 5 engineers & 67 workmen's
- Defect analysis & action implementation for quality improvement
- Process optimization for new dies
- Process proving at supplier end for outsourced dies
- Production improvements by (70% to 85.5%)
- Rejection reduction from 12% to 8.5% end to end
- Die set up time reduction from 300 minutes to 210 minutes by SMED concept
- Process standards preparation
- Achieved break even 4.87lacs shots, 6.18lacs qty 18machines
- Conduct process audit & correct abnormalities
- Handling Customer (Mando, Mobis, Taeyeoung, Rane, Samsung & Jtek)
- Daily PDCA on production, delivery & quality performances
- Manage production related tasks including planning, procurement, control & trouble shooting for achieving the planned periodic schedules, within budgeted parameters
- Playing vital role in rejection reduction of overall unit
- Customer handling on critical parts delivery status & stock build status
- Ensure all manufacturing activities within given budget (cost)
SENIOR-MANAGER - PRODUCTION / BUSINESS DEVELOPMENT
LOYYDS INDUSTRIAL WORK GUMMUDIPONDI
09.2019 - 10.2021
- Sr-Manager responsible for monthly production, delivery & quality
- Handling High-capacity machines such as 1250T & 1600Tton (UBE and Buhler)
- Handling 5 engineer & 20 workmen
- Defect analysis & action implementation for quality improvement
- Process optimization for new dies
- Process proving at supplier end for outsourced dies
- Rejection reduction at supplier end
- Failure analysis of CELR parts
- Process standards preparation
- Die manual preparation for each part
- Conduct process audit & correct abnormalities
- Production Planning & control
- Daily PDCA on production, delivery & quality performances
- Manage production related tasks including planning, procurement, control & trouble shooting for achieving the planned periodic schedules, within budgeted parameters
- Playing vital role in rejection reduction of overall unit
- Customer handling on critical parts delivery status & stock build status
- Ensure all manufacturing activities within given budget (cost)
PRODUCTION / MARKETING CONSULTANT
SUNBAM TECHNOLGIE
04.2019 - 08.2019
MANAGER - PRODUCTION / PLANNING CONTROL & MARKETING
AMZEN MACHINES PVT. LTD.
04.2013 - 03.2019
- Joined Green field to Production launch of Kappa & Transmission case Die casting Plant Project
- 1300 Ton & 1600-ton IDRA Die casting machine Erection work - Four Machines with fully automatic cell with ABB robot
- Onsite Training in Amtek - PUNE (1Month)
- Die casting machine Training By Machine maker
- ABB robot Training by ABB Persons AMTEK
- Kappa & Transmission case Project Production Trials & Corrections
- Kappa & Transmission case Production improvements by (70% -85.5%)
- Cycle Time optimization 130 Sec (Initial Stage)
- Cycle Time reduction to 99 Sec (Time study)
- Die set up time reduction from 240 minutes to 120 minutes by SMED concept
- Downtime reduction by autumnous (TPM) activity
- Die & Machine downtime reduction
- Optimizing the cycle time
PRODUCTION MANAGER
SRI BALAJI CASTINGS PVT. LTD
11.2010 - 03.2013
- Controlled 2PDC machines (350 Ton & 800 Ton)
- Monthly Production planning, Consumable, fettling & delivering on time
- Die change time reduction & TPM activities
- ISO - TS16949 Co-ordination
- New Product Development & New Die proving
- Cycle Time study optimization
- Die set up time reduction by applying SMED
- Sub-contract (Fettling) follows up & Job allocation
- Production consumables control & cost reduction
- Knowledge in machine trouble shooting
- Receiving PO & Schedule from Customer
- Dispatch detail & performance report update to customer
- Responsibility Customer issue (Quality, Qty), OTD, Premium Freight
- Implemented 5S & Kaizen in the shop Floor
- Conducting regular internal audit, Process audit & Development activities
- Taking care of inventory control for casting stock & Monthly inward/outward dispatches
- Customers: Ashok Leyland, Royal Enfield & GE
PRODUCTION IN-CHARGE
CASTWELL AUTOPARTS PVT.LTD.
07.2010 - 10.2011
- Joined Green field to Production Die casting Plant Project
- 100Ton to 800 ton LK, TOYO, ZITAI (Z, Z1 Series), TOSHIBA Die casting machine Erection & commissioning work - 10 Machines with fully automatic & Extractor
- Machine Application, Machine proving, New Product Development & New Die proving
- Production & Productivity improvement
- Cycle time optimization, Implemented 5S & Kaizen in the shop Floor
- Conducting regular internal audit, Process audit & Development activities
- Sub-contract (Fettling & Components) follows up & Job allocation
- ISO - TS16949 Co-ordination
SHIFT IN CHARGE
UCAL MACHINE TOOLS LTD & EOU
01.2005 - 06.2010
- Shift in charge for production, Quality, safety, 5S
- Shift work manpower allocation & Planning
- Melting Handling & Hourly metal planning
- Handling 10 HPDC machines (250T Ton to 420 Ton)
- Die & Machine downtime reduction
- Shift report preparation
- 5S' Improvement activities
- New operator training & Operator Moral improving
- Die set up time reduction from 90 minutes to 35minutes by SMED concept
- ISO - TS16949 Co-ordination
- Melting control with various type alloy combination (ADC 12, ADC 10, A380, LM24)
- Customers - Taco, Chrysler, Bajaj & Yamaha
SHIFT IN CHARGE
CRP INDIA PVT.LTD.
06.2001 - 01.2005
- Shift in charge for production, Quality, safety, 5S
- Shift work manpower allocation & Planning
- Melting Handling & Hourly metal planning
- Handling 10 HPDC machines (60 Ton to 800 Ton)
- Die & Machine downtime reduction
- Shift report preparation
- 5S' Improvement activities
- New operator training & Operator Moral improving
- Die set up time reduction from 90 minutes to 35minutes by SMED concept
- Melting control with various type alloy combination (ADC 12, ADC 10, A380, LM24)
- Customers - Maruti, Lucas-TVS, Delphi TVS, Brakes India, TVS Autolec
Education
MBA - GENERAL
PONDICHERRY UNIVERSITY
DEEE -
VALLEAMMAI POLYTECHNIC
ChennaiSkills
Excel for production tracking & KPI dashboards
Power point for review meeting & customer presentation
Conditional formatting (Highlight rejection, targets)
Data validation & dropdown controls
MIS report preparation (daily/weekly/monthly)
Accomplishments
- UCAL MACHINE TOOLS LIMITED, Best Employee - 2006
- SRI BALAJI CASTINGS PVT. LTD, Appreciation Award- Major Cost Reduction in machine Spare - 2011
- Reduce overall rejection from 14 % to < 7 % in unit (13 machines)
- Reduced metallurgical rejection from 8% to
- Reduced cycle time from 130sec to 99sec in five 1350T machines
- Got year best CFT award for implementing rejection reduction project in Hyundai ladder frame
- Achieved 100% delivery hit ratio for continuous 12 months
- Implemented poke yoke for key process parameters
Timeline
MANAGER - PRODUCTION
IL GAHNG AUTOMOTIVE INDIA PVT. LTD.
05.2023 - Current
MANAGER - PRODUCTION
MK TRON AUTOPARTS PVT. LTD.
11.2021 - 05.2023
SENIOR-MANAGER - PRODUCTION / BUSINESS DEVELOPMENT
LOYYDS INDUSTRIAL WORK GUMMUDIPONDI
09.2019 - 10.2021
PRODUCTION / MARKETING CONSULTANT
SUNBAM TECHNOLGIE
04.2019 - 08.2019
MANAGER - PRODUCTION / PLANNING CONTROL & MARKETING
AMZEN MACHINES PVT. LTD.
04.2013 - 03.2019
PRODUCTION MANAGER
SRI BALAJI CASTINGS PVT. LTD
11.2010 - 03.2013
PRODUCTION IN-CHARGE
CASTWELL AUTOPARTS PVT.LTD.
07.2010 - 10.2011
SHIFT IN CHARGE
UCAL MACHINE TOOLS LTD & EOU
01.2005 - 06.2010
SHIFT IN CHARGE
CRP INDIA PVT.LTD.
06.2001 - 01.2005
DEEE -
VALLEAMMAI POLYTECHNIC
MBA - GENERAL
PONDICHERRY UNIVERSITY
Trainings Attended
- Certified on problem solving through 7 QC Tools
- Attended Die casting process Training
- Completed Acheson Auto sprayer programmed Training
- Completed Robot training (ABB)
- Completed Daily work management & Production plan Training
- Attended personal effectiveness training.
- Attended NADCA process training conducted at Bangalore
Key Contributions
- One of the judges for internal QC circles project evaluation.
- Leader in productivity improvement study and Overall equipment efficiency (OEE).
- Implemented Poke Yoke /Mistake Proofing techniques that prevent scrap generation and rework by eliminating Human Errors in manufacturing processes.