Summary
Overview
Work History
Education
Skills
Languages
Timeline
Generic
ILAYARAJA T

ILAYARAJA T

Viruthunagar

Summary

Production and Process Manager with 17 + years of experience in composite manufacturing, including wind turbine blades and large FRP components. Proven expertise in managing end-to-end production operations, process engineering, and infusion technologies. Strong track record in improving productivity, reducing cycle time, and maintaining consistent product quality. Experienced in leading shop-floor teams, production planning, and continuous improvement initiatives. Adept at supporting new product introduction, process standardization, and operational excellence.

Overview

18
18
years of professional experience

Work History

Assistant Manager Process and Manufacturing

BFG international private limited
Sri City, Andhra Pradesh
05.2024 - Current
  • Monitored and controlled manufacturing processes to ensure product quality and optimize raw material and consumable usage.
  • Led continuous improvement activities and process trials for new product development (NPD) in coordination with R&D teams.
  • Applied strong working knowledge of epoxy, polyester, and phenolic resin systems for composite manufacturing.
  • Developed samples, SOPs, work instructions, and process parameters to meet customer and design requirements.
  • Planned and implemented infusion strategies for spinner and boat components, ensuring correct layer sequence and process compliance.
  • Improved productivity through defect analysis, root cause actions, tooling improvements, and effective production planning and team training.

Sr.Engineer Production

indocool composites private limited
Trichy
08.2023 - 05.2024
  • Planned and managed daily rotor blade production with strict control on schedule, manpower, and material usage as per BOM.
  • Led cycle time study and process optimization, achieving reduction from 110 hours to 40 hours in blade production.
  • Monitored shift schedules, production output, and documentation to ensure daily target achievement.
  • Developed team capability through quality awareness training and effective 5S implementation, improving shop-floor discipline.
  • Improved overall SQCDP performance and reduced infusion repair through process improvement in core finishing.

Sr.Engineer Blade Manufacturing Process

indutch composites technology
Chennai, Trichy
12.2021 - 07.2023
  • Planned and executed process material placement and infusion sequence for blade shells and small composite parts.
  • Prepared process material layouts and diagrams including release film, mesh, and peel ply arrangements.
  • Conducted SAT for new blade moulds and verified jigs and fixtures for spar cap and shear web positioning.
  • Supervised lay-up sequence in moulds to ensure compliance with process and design requirements.
  • Monitored shop-floor production, analyzed quality issues, and implemented corrective actions to prevent deviations.
  • Planned production schedules and ensured processes were controlled and followed during shifts.
  • Conducted trials to reduce cycle time and minimize defects during moulding and infusion stages.
  • Supported continuous production and quality improvements through effective resource planning, team coordination, and strong safety awareness.

Senior Production Supervisor

Pinak International
Chennai
10.2018 - 12.2021
  • Managed molding production operations with strong focus on productivity improvement and schedule adherence.
  • Led production planning and supervised the complete molding team to achieve daily and project targets.
  • Supported development and manufacturing of automotive prototype composite parts.
  • Conducted operator training and implemented 5S practices to improve shop-floor discipline and efficiency.
  • Played a key role in composite mould development and new carbon-fiber manufacturing methods for Mahindra W601 tailgate, doors, and Z101 console components.

Production Line Team Leader

VBK fibro Tech Industries
Chennai
01.2016 - 10.2018
  • Created and executed production and process plans for wind and non-wind composite products using hand lay-up and infusion processes.
  • Led production planning and team execution for Pioneer 24 m blade molding and post-molding operations with effective shift management.
  • Developed and implemented production plans for Gamesa G114 spinners, ensuring smooth material control and team coordination.
  • Managed manufacturing of FRP products including portable toilets, large acid tanks (1,000–50,000 L), spinners, nozzle covers, and Clean India family and community bins.
  • Drove continuous improvement initiatives including 7-waste analysis, resulting in cycle time reduction from 20 hours to 12 hours in 24 m blade molding.
  • Achieved consistent zero-defect production for Gamesa G114 spinners, wind nozzle covers, and government Clean India project components.

Blade Manufacturing Sr. Associate in

LM Wind Power Technology Blades India (P) Ltd
Bangalore
12.2007 - 07.2014
  • Managed molding production operations with strong focus on productivity improvement, quality control, and schedule adherence.
  • Planned and monitored daily production through effective manpower utilization, online process tracking, and team supervision.
  • Led throughput time reduction initiatives using structured process studies, Pareto analysis, and standardized work allocation.
  • Drove defect elimination in molding operations through process sequence optimization and root cause analysis.
  • Implemented continuous improvement and waste reduction initiatives under “Fuel for Growth” using waste walks, 5S, and consumable reuse.
  • Developed and trained production teams, resolved pilot-stage issues, achieved cycle time reduction, and received Best 5S Team recognition.

Education

Diploma in Mechanical Engineering - Mechanical

Arasan Ganesan Polytechnic Collage
Sivakasi
05-2006

Skills

  • Process optimization
  • Quality control
  • Manufacturing planning
  • Composite materials
  • Defect analysis
  • Production scheduling
  • Team leadership
  • Continuous improvement
  • Problem solving
  • Training development
  • Time management
  • Cost control
  • Cost reduction
  • Employee scheduling
  • Customer service and satisfaction

Languages

English
Intermediate (B1)
B1
Tamil
Native
Native
Kannada
Elementary (A2)
A2
Hindi
Beginner
A1

Timeline

Assistant Manager Process and Manufacturing

BFG international private limited
05.2024 - Current

Sr.Engineer Production

indocool composites private limited
08.2023 - 05.2024

Sr.Engineer Blade Manufacturing Process

indutch composites technology
12.2021 - 07.2023

Senior Production Supervisor

Pinak International
10.2018 - 12.2021

Production Line Team Leader

VBK fibro Tech Industries
01.2016 - 10.2018

Blade Manufacturing Sr. Associate in

LM Wind Power Technology Blades India (P) Ltd
12.2007 - 07.2014

Diploma in Mechanical Engineering - Mechanical

Arasan Ganesan Polytechnic Collage
ILAYARAJA T