Results-driven and dedicated with wide-ranging experience in leading operations for Automotive and Chemical industries. Believe in people development and empowerment in achieving mission critical projects. Proven success in accomplishing the goal through innovation and collaboration with all stakeholders; Fostering high performance teams in achieving organization goals. Establish effective quality assurance and safety programs, encouraging proactive participation across the manufacturing floor. Passionate Project Management Professional excited to partner with Business leaders to produce outstanding results in Manufacturing & Operations.
Hi, I’m
P. PARTHASARATHY
Chennai, Adambakkam
Summary
Overview
33
years of professional experience
Work History
PPG ASIAN PAINTS PVT LTD
PLANT HEAD
02.2017 - Current
Job overview
- Leading the team of 400+ people to manufacture paints and coating for Auto OEMs & Industrial customers in India
- Accountable for Three operational plants
- Designated Factory Manager for Sriperumbudur Plant, to comply with all statutory obligations to
- Government of Tamil nadu and Government of India, towards safe operation of plant, Sustainable
- Environment and Good health of employees
- Accountable for Environment, Health & Safety, Production Planning, Production, Manufacturing
- Process Engineering, Quality Assurance, Warehouse & In direct Purchase, Maintenance
- Engineering & CAPEX Projects, Plant HR, ER & IR, Plant Accounts & Administration, Manufacturing
- Excellence thru LEAN – Six Sigma
- Operations:
- Demonstrated efficient operation of PPGAP owned Manufacturing plant and two of contract manufacturing facilities
- The facilities work in synchronous to manufacture precision Paints and Coatings for Automotive Industries-Passenger cars, trucks, and two wheelers, Industrial coatings viz, Roof sheets and Aluminum cladding etc, complying to all statutory and PPG Global EHS requirement
- Improved and Sustained OEE at > 85% since 2019
- Achieving the plant objective of 98% OTIF, at 3% reduced operating cost YOY since 2019
- Coached and build high performance team with a purpose and vision for the plant, fostering capabilities to meet the talent pipeline for near future and beyond
- Developed ambitious Manufacturing Strategy and lived through to demonstrate effective planning and reaped the benefit for the organization
- Improved Cycle time by 37%,
- Productivity by 23% and achieved 12% reduction of Cost per liter from 2018
- Periodically reviewed the manufacturing strategy and plans to align with dynamic business demands, to identify capacity requirement and executed CAPEX projects
- Optimize the
- Operating revenue on operating assets and Maximize asset utilization through LEAN and
- Six Sigma
- P.Parthasarathy, +91 99625 44050 2
- Executed Brown field project at Sriperumbudur plant for manufacturing of Auto Plastic paint through state of art Dispensing equipment
- Expanded the infrastructure for manufacturing of Industrial paints, including design of machineries, processes, training and transition new products start up
- Operation and Capital budgeting for the Plants, Effective control on spend through collaboration with the team, and executing cost saving projects in all sphere of manufacturing
- Implement apt Product costing model for business proposals, enabling business growth and acquire new customers
- Lead and improve operational metric of manufacturing viz, EHS- Lead & Lag metric, Quality performance – achieve 65% NPS, Customer complaint resolution, Batch Quality
- Performance Index, Productive-lt per manhour, Cost per Liter
- Digitalize Process monitoring and controls to improve the process capability in manufacturing, through PLC & DCS programming
- Retrofitted with IOT and smart devices towards Manufacturing 4.0, a Digital – Flexible – Smart manufacturing process
- Adapt and leverage Machine learning and Artificial intelligence to predict, and leap forward on process capability index
- Benchmark process capability to PPG Global, adopt and leverage PPG Way to Lead
- Transformed Colour quality assurance process to digitalized Liquid Colour matching capability to significantly reduce the cycle time, and eliminate paint booth operations
- Obtain certification and comply to IATF 16949 – Automotive standards, ISO 9001 – Quality
- Standards, ISO 14001 – Environment Standards, PPG EHS Assurance certification – PPG
- Global EHS standards, 4 Star EHS Award from CII
- Developed and implemented Business continuity process for potential business risk, including natural calamities and induced threats, viz, Cyclone, Labour unrest & strike etc
- Synchronous collaboration with various stakeholders – Employees, PPG teams, Asian
- Paints teams, Government, Vendors, Suppliers, & Unions, to align and deliver plant vision and objectives
- Supply Chain:
- Demand forecast for 800+ SKU’s and fulfill the requirement at right quality, at right quantity and at right cost
- Plan, Schedule and Execute logistics for 1200+ Raw materials from supplier base of 300 includes imported and feed manufacturing plant
- Just-in-time delivery of paints and coating to 120+ Auto OEM and Tier I customers
- Achieve 75 days of inventory for RM & FG, using SAP and ENVISION platforms
- Enable achieve 97% OTIF, and Cash turnaround of 90 days
- Leverage SAP data analytics and automate reports to deliver BOM, Lead time (LT), Reorder level (RL), Safety Stocks (SS) etc
- Monitor warehouse inventory and maintain with in approval limits as per Hazardous chemical storage requirements
- Ensure safe operation of warehouse, complying to PPG
- EHS requirements
- Compliance to FIFO and SAP, KANBAN policies, Material tracking by the operations team
- Use of LEAN methodology and KAIZEN, eliminate waste in operation towards cost reduction and manage working capital to achieve the business goals
- Introduced Auto alerts and Reordering of Raw material in bulk tanks through integrating
- PLC and SAP
- Periodically review and collaborate with R&D team to minimize slow moving, manage return of rejects and improve space utilization in warehouse
- Coordinate with Strategic sourcing of Intermediates, Solvents, Production consumables at competitive pricing strategies to meet the business demands
- Develop and review supplier engagement strategy for 250+ suppliers/vendors to achieve mutual value creations
- This includes Process studies to identify Quality improvements
- P.Parthasarathy, +91 99625 44050 3 opportunities, Waste Elimination through LEAN and training to improve awareness and compliance
- As Go Green strategy, Sourced Plant Electricity supply from Wind and Solar power generators to support CO2 reduction, developed and executed elimination of Restricted
- Chemicals in manufacturing viz, heavy metals, carcinogenic chemicals, etc, Enabled reuse of packing materials and achieved reduction 30% in last 3 years
- Execute Operations Excellence at Outside Processing units in South India
- Continuously strive to evaluate and guide the OPCs, in effective utilization of resources – RM, PM, Energy and People
- Few Triumphs
- Increased productivity by 23% and Reduced Batch cycle time by 37%, to achieve saving of a crore since 2019
- Enhanced material utilization to 12% adding INR 9.0 Crore to bottom line YOY
- Augmented capacity to manufacture 17500KL through capital and operation efficiency
- Executed Brown field project in existing plant, with zero incident, on time and on budget
- Rolled out Online monitoring for product performance as perceived by customer, to reduce rejection to 1.2% on COGS from 3.5%.
PPG ASIAN PAINTS PVT LTD
COUNTRY EHS MANAGER
03.2013 - 01.2017
Job overview
- Developed strategy and rolled out for Environment, Health & Safety management across all location & teams in India in compliance to India regulation & PPG Global EHS Management system
- Responsible and accountable for Statutory compliance and PPG Global EHS requirements for 4 manufacturing plant, 2 R&D labs, 12 office locations and 42 warehouses
- Develop engineering standards for plants, warehouse and offices for PPG Asian Paints
- Obtained Environment clearance and License for Green field Resin manufacturing plant in Gujarat
- Coordinated with State and Central Government for necessary approvals, and coordinated for execution of project from ground breaking to production start up within 15 months and within budget of INR 200 Crore
- Carried out due diligence for around 6 manufacturing companies, and successfully completed Merger & Acquisition for two manufacturing plants in India
- Also executed due diligence to exit a business & manufacturing plant
- Develop needed strategy and execute plans for manufacturing paints, coatings at contracted locations
- Frequently monitor contract locations (around 9 spread across
- India) to meet the EHS requirements
- Train and improve compliance at these plants
- Collaborated with Business and Operations team in integrating business & operations to meet PPG Global EHS standards
- Adapt and drive Global EHS metrics across businesses and operations
- Develop improvement plans and execute projects focusing on PPG sustainability and go-green strategy
- Obtained PPG Global EHS compliance certification for 4 manufacturing plants and 2 R&D labs in India
- Align and certify Chemicals to meet the PPG Global Product Stewardship requirements.
PPG ASIAN PAINTS PVT LTD
MANAGER
02.2011 - 02.2013
Job overview
- Conceptualized Process design and executed the Project for manufacturing of CED &
- Primer paints and Tinters for expansion to meet the volume increase of 10000 KL/annum
- P.Parthasarathy, +91 99625 44050 4
- Expanded Warehouse and bulk tank capacity to meet the production capacities at plant
- Augment capacity of utilities to meet the increased Power, Water, Compressed air,
- Nitrogen & Process cooling
- Commissioned and standardized production within Project timeline and capital sanction
- Established Engineering Procurement & Purchase processes, Maintenance Management
- Processes, and Contract Management processes in the plant
- Introduced TPM and Initiated Autonomous Maintenance for the plant.
JOHN DEERE INDIA PVT LTD
EXECUTIVE MANAGER
05.2008 - 01.2011
Job overview
- Executed Electrical Substation of 132 KV / 22 KV for 25MW capacity
- Project coordinated with MSEDCL, MSETCL & CEIG
- Managed the operation of Plant facility engineering team spread over 115 acres and 300+ employees
- Executed Water pipeline project to draw water from River and treatment plant for use of 10MLD water at factory
- Expanded Tractor Paint shop with auto dip CED and Robo spray booths for manufacturing of 35000 tractors per annum
- Sourcing of engineering materials and services to execute facilities expansion and manufacturing expansion projects of INR 150 Crore annually
- Upgraded Electrical system, Plant Ventilation system, Compressors system, LPG Gas storage and distribution system, Bulk oil and fuel storage & distribution system for the plant
- Augmented machining capacity with CNC machining centers, PLC & SCADA for process monitoring
- Constructed Administrative block and Process verification lab for the plant
- Transitioned operation of utilities to outsourcing – cost saving initiative
- Located and build factory for JD Water Technology division at Vadodara
- Monitored and ensured Compliance to all Plant Statutory requirement and John Deere
- Corporate Compliance requirement
- Certification for Plant EHS and Fire safety from FM
- Global standards.
FOSECO INDIA LTD
ENGINEERING MANAGER
05.2006 - 04.2008
Job overview
- Executed project for Dry Aluminium powder blending process
- Expanded Electrical and other utilities to meet the production capacity
- Modified and improved the effectiveness of Effluent treatment plant, to enable recycle of treated water into process
- Managed the Plant Engineering team of 20+ employees
- Implemented Autonomous Maintenance for the plant.
ASHOKLEYLAND LTD
SENIOR ENGINEER
10.1995 - 04.2006
Job overview
- Paint Shop Project & Engineering, Hosur II Plant, Hosur
- Green Field project for Automotive Truck manufacturing in collaboration with IVECO, Italy
- P.Parthasarathy, +91 99625 44050 5
- Executed project for Painting of Commercial vehicle Cabins, Frame side members & Axles
- Installation and Commissioning of Pre Treatment, CED, Manual and Robotic spray application, Ovens, and sealant application booths
- Installation of utilities viz, Electrical HT installations, DG’s, Air Compressors, Water treatment plants, Water distribution system, Chillers, AC’s etc
- Operation and Maintenance of Effluent and Sewage Treatment plants, including solid waste management and disposal
- Development of design in coordination with supplier, Pre installation inspections, civil work coordination, and standardization of bought out items
- Coordination with various suppliers, contractors & functions for smooth execution of project
- Carryout project review for targeted completion
- Coordination with Corporate Project Planning, System implementation
- Introduction of PLC and SCADA based conveyors for cabin and frame handlings at Pre treatment and Paint shops
- Commissioning of material handling equipment – viz – Under slung cranes, EOT Cranes,
- Forklifts, Mobile boom cranes, tuggers, trailers, Side loaders
- Build and commissioning of Effluent and Sewage treatment plants, Hazardous waste handling and Storage sheds
- Managed facility management team of 120+ employees, spread over 500 acres of facility
- Implemented various project on Energy conservation, Water conservation, and waste reduction.
DCM HYUNDAI LTD
ENGINEER
09.1994 - 09.1995
Job overview
- Poliwakkam plant, Thiruvallur
- Green field project for manufacturing of Marine Freight container, in collaboration with
- Hyundai, South Korea
- Project executed in 9 months period
- Involved in foundation design of equipment, fixtures, executed in coordination with Architect and Civil contractor
- Project Execution of Utilities, Gas generators & vapourizers, Material handling cranes, winches, trucks etc
- Installation and Commissioning of Presses upto 350 Ton capacity
- Press brakes, Rolling mills, Paint lines, finishing lines, Proto testing facility and Admin building
TI DIAMOND CHAINS LTD, Ambattur
JUNIOR ENGINEER
11.1991 - 08.1994
Job overview
- Maintenance of equipment and machineries, viz, Presses – hydraulic and mechanical,
- SPM’s, Material handling system, Tool room, Heat treatment furnaces-batch and continuous types, Metal finishing system, High speed Chain assembly machines, Testing facility for chains, packing equipment
- Management of Spares for utilities and machineries
- Work deployment and ensure completion of Breakdown on time
- Plant and Execute Preventive Maintenance for all machines
- P.Parthasarathy, +91 99625 44050 6
- Operation of Effluent Treatment plant, Chiller plant, and Air Conditioning units.
Education
BITS
MASTER IN SCIENCE from – MANUFACTURING TECHNOLOGY
University Overview
GPA: 7.8, Supply Chain Management, Strategy development & Deployment, Flexible Manufacturing
technology, Digital – Automated Manufacturing, Strategic decision making.
BITS
BACHELOR from SCIENCE – ENGINEERING TECHNOLOGY
University Overview
GPA: 7.9, Mechanical engineering, Industrial Planning and roll out, People, Process & Product Design
Development, Development
Skills
- Supply chain and Manufacturing strategy
- Flexible manufacturing strategy
- Strategic Sourcing, Purchase and Cost
- Business financials and growth planning
- Budgeting, Cost optimization and control
- Cost saving Projects
- Facility Planning and Execution
- Engineering, Automotive & Chemical
- Industries
- Deploy Environment, Health & Safety
- Strategy
- Build High Performance team
Timeline
PLANT HEAD
PPG ASIAN PAINTS PVT LTD
02.2017 - Current
COUNTRY EHS MANAGER
PPG ASIAN PAINTS PVT LTD
03.2013 - 01.2017
MANAGER
PPG ASIAN PAINTS PVT LTD
02.2011 - 02.2013
EXECUTIVE MANAGER
JOHN DEERE INDIA PVT LTD
05.2008 - 01.2011
ENGINEERING MANAGER
FOSECO INDIA LTD
05.2006 - 04.2008
SENIOR ENGINEER
ASHOKLEYLAND LTD
10.1995 - 04.2006
ENGINEER
DCM HYUNDAI LTD
09.1994 - 09.1995
JUNIOR ENGINEER
TI DIAMOND CHAINS LTD, Ambattur
11.1991 - 08.1994
BITS
MASTER IN SCIENCE from – MANUFACTURING TECHNOLOGY
BITS
BACHELOR from SCIENCE – ENGINEERING TECHNOLOGY
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