Hi, I’m
Murugadoss Elumalai
Senior General Manager - Methods & Industrialization
Hyderabad
Summary
Dynamic professional with a robust background in industrialization, engineering, smart manufacturing, and project management, focused on enhancing industrial performance and elevating customer experiences. Expertise in building high-performance teams and nurturing the next generation of technical engineers and leaders within both the organization and the industry. Committed to transforming traditional manufacturing setups into smart environments through the application of Industry 4.0 principles and strong cybersecurity measures. Passionate about driving innovation and achieving operational excellence in an ever-evolving technological landscape.
Overview
25
years of professional experience
2
Languages
Work History
Schneider Electric India Pvt. Ltd.
Senior General Manager – Methods & Industrialization
05.2024 - Current
Job overview
- Managing two manufacturing plants with 15 engineers and managers for methods and industrialization activities.
- Drive transformation projects in line with the organization’s winning plan.
- Collaborate with BU, Global Industrial Deployment and Performance Team to define the Long-Term Industrial Plan (LTIP), industrialize the manufacturing line, and define the end-to-end supply chain.
- Responsible for people management, including goal setting, performance management, competency development, rewards and recognition, engagement, and wellbeing.
- Smart Manufacturing Deployment and Adoption Improvement: Digitization, IIoT, Industry 4.0 Implementation.
- Capacity management – Decide on a smart and stepwise investment strategy for CapEx investment decisions, as required by the Rolling Forecast (RF), to ensure the profitability of the investment.
- Conceptualizing, design validation, and implementation of low- and high-end PLC/PC-based automation for lean manufacturing assembly lines, as per Line Architecture and Design Methodologies (LADM).
- CapEx and OpEx budget preparation and management. Currently managing 28 projects/lines with a CapEx value of 14 million euros.
- Plant re-layout change to improve MPH (Material Providing and Handling) and effective utilization of space.
- Manage continuous improvement concerning line architectures, capacities, capabilities, and time referential.
- Schneider Performance System (SPS) - Product and Process Domain Auditor.
- Refurbishment and localization projects to improve safety, quality, and efficiency, and reduce costs.
- Guiding team to Implement Kaizen & Lean Six sigma projects to improve industrial performance and Customer Experience
- Regular interaction and collaboration with Regional & international team for Sharing / Benchmarking the Best practices
Schneider Electric India Pvt. Ltd.
General Manager – Methods & Maintenance
06.2018 - 04.2024
Job overview
- Drive transformation projects in line with the organization’s winning plan.
- Collaborate with BU, Global Industrial Deployment and Performance Team to define the Long-Term Industrial Plan (LTIP), industrialize the manufacturing line, and define the end-to-end supply chain.
- Responsible for people management, including goal setting, performance management, competency development, rewards and recognition, engagement, and wellbeing.
- Smart Manufacturing Deployment and Adoption Improvement: Digitization, IIoT, Industry 4.0 Implementation.
- Capacity management – Decide on a smart and stepwise investment strategy for CapEx investment decisions, as required by the Rolling Forecast (RF), to ensure the profitability of the investment.
- Conceptualizing, design validation, and implementation of low- and high-end PLC/PC-based automation for lean manufacturing assembly lines, as per Line Architecture and Design Methodologies (LADM).
- CapEx and OpEx budget preparation and management. Currently managing 28 projects/lines with a CapEx value of 14 million euros.
- Implement Poka-yoke and Jidoka to reduce FFR, MDR, and NQC.
- Plant re-layout change to improve MPH (Material Providing and Handling) and effective utilization of space.
- Monitoring and identifying the waste through SIM – KE, analyze, and improve industrial efficiency, IE.
- Refurbishment and localization projects to improve safety, quality, and efficiency, and reduce costs.
- Providing a low-cost automation solution to eliminate PQCS, PCQP, and FMEA-derived potential failure modes.
- Guiding the team to implement Kaizen and Lean Six Sigma projects to improve industrial performance and customer experience.
- Regular interaction and collaboration with the regional and international teams for sharing and benchmarking the best practices.
- Conduct VSM and Kaizen Blitz sessions to identify waste and implement the identified opportunities through projects.
Schneider Electric India Pvt. Ltd.
Senior Manager - Automation & Maintenance
11.2011 - 05.2018
Job overview
- Conceptualizing, design validation, and implementation of low- and high-end PLC/PC-based automation for lean manufacturing assembly lines
- Smart Manufacturing Deployment and Adoption Improvement: Digitization, IIoT, Industry 4.0 Implementation.
- Optimize cycle and improve capcity wit Frugal automation solutions
- TPM Deployment
- CapEx and OpEx budget preparation
- Implement Poka-yoke and Jidoka to reduce FFR, MDR, and NQC.
- Monitoring and identifying the waste through SIM – KE, analyze, and improve industrial efficiency, IE.
- Refurbishment and localization projects to improve safety, quality, and efficiency, and reduce costs.
- Providing a low-cost automation solution to eliminate PQCS, PCQP, and FMEA-derived potential failure modes.
- Implement Kaizen, Lean Six Sigma projects.
- Train and mentor the team on automation programming.
- Deploy automation standards across the plant.
- Root cause analysis and predictive maintenance.
Applied Materials India Pvt. Ltd.
Technical Lead – Applied Global Services Dept.
07.2008 - 10.2011
Job overview
- Handling a Team of 10~15 members in Installation & Erecting of Vacuum based Glass coater, Vacuum based web coater(metalise) electromechanical components & devices Installation & Maintenance
- Poisoning & leveling of machine glass coater & Metalise (Chamber & Winding rail)
- Installation & Commissioning of Following Sub-systems
- High voltage power supplies (Huttinger & AE)
- Polycold,Telemark, Optoplex II IP, Optoplex III IP (Carl Zeiss)
- PCC,MCC,PLC control panels for the machine
- AC / DC Drives, Vacuum Pumps (Diffusion, TMP, Rotary vein, Roots) , Vacuum pump lines
- HMI (Human Machine Interface), integration of Field I/Os through control net / Device net scope of supply.
- Develop work assignment for Technicians/contractors to uncrate and stage the glass coaters, web coaters scope of supply.
- Supervise the Technicians/Contractors to assemble as per technical documentation. The mechanical and electrical scope of supply.
- Attending warranty / service breakdowns for glass coater, web coater(metalise) Electrical & mechanical
- Perform process testing of glass coaters and adjust process parameters to enable the coater to confirm to contractual requirements.
- Helium Leak deduction test
M/s. ILJIN Automotive Private Ltd (Hyundai Ancillary)
Engineer
02.2005 - 07.2006
Job overview
- Maintenance of different kinds of CNC macines ( HMC,VMC & TC) and SPM machines (120+ machines)
- Preventive & Reactive Maintenance
- Shift Incharge for Maintenance function
- ISO/TS 16949, ISO 9001, ISO 14001, and OHSAS 18001.
M/S Kar Mobiles Ltd (Rane Group)
Assistant Engineer
09.2003 - 01.2005
Job overview
- Maintenance of MIG & TIG welding machines, Forging machines, Grinding machines, Heat Treatment & Plating plants, Induction Hardening, Furnaces, Utilities Equipment
M/s. Showa Engineering (TVS Group)
Trainee Engineer
05.2000 - 06.2003
Job overview
- Maintenance of Automatic bar loading Lathes , Grinding machines, Hydraulic and Pneumatic presses
Education
IGNOU
MBA from Operations Management
04.2001
BITS Pilani
Bachelor of Science
04.2001
IETE
Diploma from Electronics and telecommunication
Skills
Industrialization & Technology- Automation , PCBA Process & Test, Certified Lean Six-Signa GB, Certified Practitioner of MTM-1 (Motion study analysis) and Advanced Lean Practitioner
PLC Programming ( SFC, ST,Ladder & FBD) & HMI Programming
Nationa Instruments (NI) trained (Core1,2 & 3) LabVIEW programmer ; SQL Programming & NI Test Stand
Conceptual Design, Development , Qualification of SPMs for Assembly product Testing and Packaging
Marking & Printing technologies : Trumpf & Rofin UV Laser Marking, RF Testers, Markem imaje & Domino Ink Jet Printers, Zebra,Sato - Label printers
AI based Smart Scanners & Vision systemsScanners & Vision Systems : Cognex, Sick, Omron, Keyence, Symbol, NI make
Installation/commissioning/ FAT Sign off - Glass coaters, Web Coaters (Metalizer)
Maintenance of CNC machine’s Spindle units, ATC & APC Servicing of Hydraulic motors, Valves and Cylinders Riveting systems (Baltec & Gullmen make), Pick & Place unit service Index unit gear box (Sopap, Destaco,etc) service, Conveyor Systems, Jigs and Fixture
Pneumatic and Hydraulic Systems :Troubleshooting of Pneumatic & Hydraulic circuits having components of Festo, Aventics and SMC, Rexroth, Yuken, etc
Standards Awareness & Implementation : TPM,IMS ,ISO-50001
Calibration : Screw drivers, Nut runners, High voltage Leakage test unit, Voltage & Current sources – MTE, Rotek,etc
Industry Experience : Switch Gear, Automobile, Process Industries and EMS
Accomplishments
- No major safety incidents to human and no major damage to asset
- Deployed Smart Manufacturing tools to become a Standard Smart factory as per Schneider guidelines
- Built a new Manufacturing line with all the necessary protocols as per IEC62443 SL2 Cyber Security and Certified by TUV
- Optimized 680 Sq.M space through Lean Transformation which had helped to bring in 20M Euro business for plant
- DLP (Direct Labour Productivity) saving of >10% through multiple projects to reduce Design Time and Efficiency improvement for last 3 years. 130K+ Euro Saving every year
- Contributed with team to Plant’s consistent revenue growth of >15% in last 5 year , Except 2020 COVID year.
- Introduced End to End traceability for products
- Industrialisation of new Semi-Automatic MCB manufacturing Lean Line - Hourly Rate of 1200 MCBs/Hour
- >10% Opex cost reduction for last 3 years by indigenising the spares and implementing Predictive & Preventive Maintenance
- Energy consumption reduction by ~15% continuously 3 years
- Continue to build high performance, Diversified team and supported their career growth in Schneider Global & in India
- Edison Expert-Potential in the filed of Automation by Schneider Electric Global
- Product Innovation - Conceptualized and designed a Constant current source for low current (2.5mA) continuity test, to eliminate frequent customer complaint. This solution was horizontally deployed in all the plants in Schneider where this product is manufactured
- Lean Six Sigma project – Multiple Lean Six sigma projects to Improve efficiency, Delivery and Quality
- Got trained by SE-Global Program management on OJAS Leadership Program & LFPG (Leadership for Profitable Growth)
- 23 manpower optimized through Small Automation projects (ROI less than 2 Years)
- MTTR reduced to 30 Min , by standardising the PLC and HMI programmes with easily understandable SFC (Grafset) and Standardization of HMI PLC & HMI Programming
- Implemented many Jidoka and Poka yokes in the assembly line to reduce RPN
- Process Lead time reduction in Vacuum Heat treatment process from 96to75 Hours. Scrap reduction of 13K Euro
- Level 4 in COMET Technical Competency – LADM (Line Architecture Design Methodology, Functional Test Technologies, Vacuum Heat Treatment and Resin Filling process
- Received PWMD Yearly Award (Person who makes difference) from Schneider Electric - Country Managing Director
- “Team of the Quarter” by Applied Materials
Timeline
Senior General Manager – Methods & Industrialization
Schneider Electric India Pvt. Ltd.
05.2024 - Current
General Manager – Methods & Maintenance
Schneider Electric India Pvt. Ltd.
06.2018 - 04.2024
Senior Manager - Automation & Maintenance
Schneider Electric India Pvt. Ltd.
11.2011 - 05.2018
Technical Lead – Applied Global Services Dept.
Applied Materials India Pvt. Ltd.
07.2008 - 10.2011
Engineer
M/s. ILJIN Automotive Private Ltd (Hyundai Ancillary)
02.2005 - 07.2006
Assistant Engineer
M/S Kar Mobiles Ltd (Rane Group)
09.2003 - 01.2005
IGNOU
MBA from Operations Management
04.2001
BITS Pilani
Bachelor of Science
04.2001
Trainee Engineer
M/s. Showa Engineering (TVS Group)
05.2000 - 06.2003
IETE
Diploma from Electronics and telecommunication