PETER PAULRAJ A
Coimbatore / Bangalore
Summary
Senior Manager with extensive experience in driving business excellence and optimizing plant operations. Expertise in lean manufacturing and people management, leading initiatives that enhance efficiency and reduce costs. Proven ability to foster a culture of continuous learning and high-performance teamwork. Over 15 years in aerospace connectors manufacturing, excelling in operational strategy and financial management./ LSSBB
Overview
23
23
years of professional experience
1
1
Certification
Work History
Sr. Manager - Operations
Turbo india interconnect solutions
Coimbatore / Bangalore
01.2022 - Current
- Spearheaded multi-department operations, ensuring seamless integration between machining, plating, assembly, PPC, methods, tool room, and maintenance.
- Responsible for managing CapEx and OpEx across operations.
- Analyzing 1+3 forecast & production planning and arranging resources within the stipulated timeline.
- Establish standards, OEE Analysis, Quality, Cost & People Mgmt.
- Establish and control all operational processes under the leadership of the Process Engineering team.
- Facilitating War Room meetings to monitor and drive daily operational efficiency across all departments.
- Overall responsibility in ensuring efficient utilization of equipment and facilities.
- Building a culture of structured problem solving, data-driven decision making, Health & safety and continuous learning at all levels.
- Lead the Business Excellence Committee and plan, manage, and direct the site's overall continuous improvement program to drive operational excellence and achieve strategic objectives.
- Provide training in Continuous Improvement (CI), coach and mentor cross-functional teams and individuals on Lean processes, and foster a culture of continuous improvement across the organization.
- Manage sales targets and align operations to effectively achieve revenue goals.
- Closely working with top management to develop a roadmap for business excellence.
- Working on a greenfield project to develop a new facility (Auto Plating Line, Assembly Shop, Cable Harness, and Corporate Office).
- Plan layouts, execute modifications, and enhance facilities to ensure smooth operational flow, and meet evolving requirements.
- Capacity analysis allocates resources toward a three-year business plan.
- fulfilling the AS9100 Rev D requirements throughout operations.
Asst.Manager Assembly
Eaton
12.2010 - 01.2022
- Company Overview: Aerospace and defense connector and accessories manufacturing company AS9100 Rev-D certified
- Develop and implement production schedules, allocate resources efficiently, and monitor operator performance to ensure timelines and targets are consistently met.
- Managed MIL-STD D38999 connectors and industrial, submarine, and railway connector assembly.
- Monitored and analyzed production efficiency, ensuring compliance with KPI requirements and maintaining low PPM levels.
- Collaborated with the NPD team, providing critical assembly-related inputs for new product development.
- Led Continuous Improvement (CI) initiatives, optimizing processes and improving overall efficiency.
- Implemented risk identification strategies, proactively addressing potential production issues.
- Assessed and monitored the skill matrix, identifying skill gaps and conducting targeted training programs.
- Ensured EHS (Environmental, Health & Safety) compliance and promoted a culture of workplace safety.
- Ensured Preventive Maintenance & AMC completion for all assembly equipment, minimizing downtime and ensuring reliability.
Sr. Engineer - Engineer Methods
Souriau india Pvt Ltd - Esterline - Transdigm
12.2010 - 01.2022
- Led project management activities, including technical feasibility studies and risk assessments.
- Conducted cost estimation, including Bill of Materials (BOM) and slab pricing analysis.
- Developed Process Failure Mode & Effects Analysis (PFMEA) and Control Plans to enhance quality and reliability.
- Designed process drawings using CAD & Pro-E for production planning.
- Planned cutting tools and developed special tooling, jigs, and fixtures using Pro-E & AutoCAD.
- Managed process changes control (PCR & PCN) for continuous process improvements.
- Created Work Instructions & Inspection Plans to standardize production quality.
- Provided CNC programming support to enhance machining efficiency.
- Led First Article Inspections (FAI) in coordination with cross-functional teams (CFTs).
- Drove Continuous Improvement (CI) activities, ensuring process efficiency and waste reduction.
- Coordinated outsourcing activities to optimize production capabilities and cost efficiency.
Production Supervisor
Roots Industries India Limited
01.2010 - 12.2010
Shift Supervisor
SPECTRA ALUCAST (M) SDN. BHD
01.2007 - 12.2009
CNC Setter
Autoprint Machinery Manufacturers
01.2002 - 12.2007
Quality Inspector
Sri Ranganathar Industries
01.2002 - 12.2007
Trainee
Sakthi Auto Component
01.2002 - 12.2007
Education
BE -
Karpagam Academy of Higher Education
Coimbatore, INDIA01.2018
Diploma -
Erode institute of technology
01.2001
Skills
- Business Excellence
- Strategic planning
- Plant Operations
- People Management
- Lean Manufacturing
- MIS Reporting
- Sales Revenue
- Methods
Certification
- Six Sigma Black Belt
- QMS internal auditor AS9100 Rev D
- Advanced GD&T training
- Kaizen
- Effective communication skill
- IPTES (intensive practical training on employable skill)
SOFTWARES
- AutoCAD , MS office ,MS365 ,ERP
Overseas Experience
- Represented the company at the IDET show 2023 in the Czech Republic, promoting items of business.
- Plant visit, new project development SOURIAU CHAMPAGE & MAROLLES, France, 2020.
- CNC Shop shift supervisor, Spectra Alucast, Malaysia, 2007-2009.
Accomplishments
TURBO INDIA INTERCONNECT SOLUTIONS
- Facility Expansion & Setup: Upgraded Assembly, Engineering, and Conference rooms (2022).
- Set up Cable Harness (2023), Tool Room, and Rubber Molding (2023).
- Digitalization & Process Improvements: Launched 48-hour product delivery app system through business excellence lead, digitalized the shop floor to enable paperless access to process documents, drawings, and production reports with a low-budget investment.
- Led CI Committee: 200+ kaizens (2023).
- Introduced Daily Sales Tracker & 1+3 Sales Plan - improved OTD.
- Lean & Operational Excellence: SMED implemented: CNC setup time reduced from 3 hrs to
- Developed in-house Live Tool setup (CNC Turning).
- Implemented a conveyor setup in the assembly process, reducing the start-to-pack time from 6 minutes to just 10 seconds through Lean practice.
- Strategic Initiatives: Introduced Business Plan Reviews, ERP, and AS-compliant org restructure.
- Revamped parent company TI - turned profitable in 8 months.
- Optimized headcount: Saved ₹5L/month.
- Working on a greenfield project to develop a new facility (Auto Plating Line, Assembly Shop, Cable Harness, and Corporate Office).
- Implemented Gantry type robot Automation in plating line pre-cleaning process for improved productivity & Quality - Turbo India.
SOURIAU / EATON
- Awards and Recognition: Eaton CI Global Award (2021), Superstar Award (2020), Leadership Excellence (2019), CII Poka-Yoke Runner-up (2020), Tech Innovation Certificate (2012) , Eaton CI Global Award (2021),
- Engineering & Process Breakthroughs: Led Arinc-600 (AIRBUS) connector development. Developed hermetic (glass-to-metal) sealing process.
- SMED: VMC/CNC setup cut from 4 hrs to 30 mins.
- 2 VSM projects: ₹10L savings,10% lead time cut.
- 2 Kaizen event projects: setup time reduction of 20%, and CT reduction of 32%
- Automation and Global Adaptability: Introduced glue robot, contact counter, and wire cutter automation
- Adapted to 4 global leadership styles (French & US).due to accusations
- Implemented Gantry type robot Automation in plating line pre-cleaning process for improved productivity & Quality - Turbo India.
- Optimized headcount: Saved ₹5L/month.
- Working on a greenfield project to develop a new facility (Auto Plating Line, Assembly Shop, Cable Harness, and Corporate Office).
SOURIAU / EATON
- Awards and Recognition: Superstar Award (2020), Leadership Excellence (2019), CII Poka-Yoke Runner-up (2020), Tech Innovation Certificate (2012),Eaton CI Global Award (2021),
- Engineering & Process Breakthroughs: Led Arinc-600 (AIRBUS) connector development. Developed hermetic (glass-to-metal) sealing process.
- SMED: VMC/CNC setup cut from 4 hrs to 30 mins.
- 2 VSM projects: ₹20L savings, 25% lead time cut.
- 2 Kaizen event projects: setup time reduction of 20%, and CT reduction of 15%
- Automation and Global Adaptability: Introduced glue robot, contact counter, and wire cutter automation
- Adapted to 4 global leadership styles (French & US).due to accusations
PROFILE SUMMARY
Manufacturing & Engineering Expertise
- Hands-on leadership in CNC Machining (Turning, Milling), Plating, Tool Room, SPMs & Connectors Assembly.
- Specialist in Methods Engineering, driving process innovation and efficiency.
Strategic Operations & Lean Leadership
- Proven experience in Lean systems setup, SOPs, and alignment across Process Quality, Maintenance, and Mfg. Engineering.
- Led OEE projects—data-driven improvements with measurable impact. Managed full plant operations—Machining to Assembly—achieving monthly production targets.
Business Excellence & KPI Focus
- Delivered consistent KPI growth through structured planning & execution. Strong in CapEx/OpEx management—enhancing capacity & cost control.
- Championed CI initiatives: 5S, Safety, Quality, Delivery, Cost. Lean Tools & Process Optimization Proficient in Kaizen, Kanban, JIT, Poka-Yoke, PDCA, SPC, FMEA & MSA. Led process planning, feasibility, risk and cost analysis, FAI, CP, FMEA, and CI to meet AS compliance
Timeline
Sr. Manager - Operations
Turbo india interconnect solutions
01.2022 - Current
Asst.Manager Assembly
Eaton
12.2010 - 01.2022
Sr. Engineer - Engineer Methods
Souriau india Pvt Ltd - Esterline - Transdigm
12.2010 - 01.2022
Production Supervisor
Roots Industries India Limited
01.2010 - 12.2010
Shift Supervisor
SPECTRA ALUCAST (M) SDN. BHD
01.2007 - 12.2009
CNC Setter
Autoprint Machinery Manufacturers
01.2002 - 12.2007
Quality Inspector
Sri Ranganathar Industries
01.2002 - 12.2007
Trainee
Sakthi Auto Component
01.2002 - 12.2007
BE -
Karpagam Academy of Higher Education
Diploma -
Erode institute of technology
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