Ramesh Kumar P

• Managed multiple complex projects daily under tight deadlines, ensuring timely delivery of engineering solutions.
• Reviewed production targets, tracked deviations, and prepared corrective actions to align operations with performance goals.
• Improve productivity for existing products through kaizen and quality checks.
• Design fixtures for diverse engineering parts and valve components for CNC machines.
• Develop and select tooling for CNC programming and product development.
• Create CNC programs for sample components within estimated cycle time.
• Led discussions focused on implementing changes and promoting flexible working practices, enhancing team adaptability.
• Report directly to head of operations to support planning decisions.
• Analyse customer complaints and implement corrective and preventive actions.
• Set vendor costing using process study and supplier-end audits.

Run KPI reviews across safety, quality, delivery, cost, productivity, OEE for risk reduction.

Drive kaizen, TPM, 5S/6S, poka-yoke, and VSM to strengthen continuous improvement.

Optimise loading, utilisation, cycle time, tool use, and throughput capability for efficiency.

Expand capacity to improve productivity and output reliability continuously.

Lead VTL, HTC, VMC, HMC, HBM, and turn-mill programming for steadier machining.

Develop and optimise CNC programmes for parameters, inserts, fixtures, gauges to cut variability.

Coordinate design quality, PPC production tools, engineering, and suppliers for industrialisation.

Produced standard process plans, routings, SOPs, and work instructions to ensure consistent output.

Confirm drawings to lock sequence machine choice, tooling, and cycle-time estimates.

Run RCA and CAPA actions to eliminate defects, scrap, and rework.

Maintained availability of cutting tool inserts, fixtures, and gauges to minimise stoppages and ensure smooth flow.

Aligned CNC shop operations and NPD to meet delivery targets daily.

Drive DFM and concurrent engineering to improve manufacturability and reduce process risk.

Lead NPD from drawing review through manufacturing feasibility and process planning.

Coordinate NPD readiness across design quality, production, PPC, tool engineering, purchase, maintenance, suppliers.

Develop process sequences, routing, machine selection, CNC programming, and cycle-time estimates.

Conduct trial machining, first-off and sample development, for process proving.

Transfer drawing-stage work into stable, repeatable, cost-effective serial production.

• Lead New Product Development (NPD) activities from drawing review and manufacturing feasibility through process development, sample machining, validation and production release.
• Review customer drawings, specifications and technical requirements to establish manufacturing feasibility, process sequence and cost-effective machining methods.
• Develop complete process plans, routing, machining methods and cycle-time estimates for new steel casting components.
• Coordinate with Design, Production, Quality, Tool Engineering, PPC, Purchase and Vendors for smooth execution of new product development projects.
• Develop and optimize CNC machining processes, CNC programs, tooling, inserts, fixtures and machining parameters.
• Conduct concurrent engineering with Design and Engineering teams to identify manufacturability improvements, process risks and cost-reduction opportunities.
• Develop machining processes for CNC VMC, HMC, VTL, HTC, HBM, Turn-Mill and other specialized machines based on component requirements.
• Establish suitable machine selection, operation sequence, cutting parameters, tooling and fixture concepts to achieve required quality and productivity.
• Conducted trial machining, sample development, process proving, and quality validation to ensure readiness for production release.
• Analyze and optimize machining cycle time, tool consumption, machine utilization and process capability to meet target cost and productivity.
• Identify opportunities for Design for Manufacturing (DFM), process simplification, waste elimination and cost reduction during product development.
• Develop and validate special tools, jigs, fixtures, gauges and poka-yoke solutions to improve quality and productivity.
• Support prototype and first-off component development, ensuring dimensional accuracy and process readiness for serial production.
• Prepare and standardize SOPs, process sheets, work instructions, route cards and other manufacturing documentation for new products.
• Conduct process risk analysis, quality proving and corrective actions for development-related issues.
• Coordinate with suppliers and subcontractors for outsourced machining, tooling, fixture development and process capability.
• Evaluate and finalize subcontract machining processes and costing based on process study and supplier capability.
• Ensured successful transfer of developed products from drawing board to shop floor by establishing stable and repeatable manufacturing processes.
• Drive Kaizen, Lean Manufacturing, TPM and continuous improvement initiatives during new product introduction.
• Ensure new products achieve required Safety, Quality, Cost, Delivery and Productivity (SQCDP) targets.
• Lead cross-functional problem-solving and Root Cause Analysis (RCA) during prototype and pre-production stages.
• Ensure timely completion of NPD activities within agreed quality, cost, delivery and project timelines.
• Achieved 95% customer on-time delivery.
• Manage daily production planning, ensuring timely completion of tasks and meeting quality standards.
• Review the scope of the project in collaboration with the sales Team.
• Plan which identifies and sequences the activities needed to successfully complete the project.
• Production capacity planning.
• Kaizen initiatives and continuous improvement activities.
• Improved productivity and reduced product lead time.
• Process defect elimination and standardization.
• Waste elimination by Lean concepts.
• Product Routing and meeting the project cost within an assigned budget.
• Concurrence engineering with design for the Manufacturing feasibility and cost cutting initiatives.
• Oversee machine shop operations, including manpower handling, utilization of machinery, and project management.
• Developed and implemented efficient manufacturing processes, resulting in enhanced productivity and cost effectiveness.
• Working with lean for layout fixing for new product.
• Driving cost-effectiveness across operations.
• Focusing on maintaining and improving the safety systems available on the shop floor.
• Managing the sudden crisis on manpower absent and machine failure.
• Escalate critical issues at the right time.
• Collaborate with cross-functional teams to resolve engineering issues and optimize production workflows.
• Collaborating with cross-functional teams to achieve operational goals.

• Expertise in Production Planning & Control (PPC), capacity planning, and resource utilization.
• Achieved monthly production targets, including outside machining.
• Ensure achievement of production targets, delivery schedules, and customer commitments.
• Drive productivity improvement, cost reduction, waste elimination, and profitability enhancement initiatives.
• Lead overall CNC Machine Shop operations and production management.
• Ensure optimal utilization of CNC machines and manpower.
• Implement productivity improvement and cost reduction initiatives.
• Monitor machining cycle time and improving process efficiency.
• Controlled rejection, rework, and quality-related issues to maintain production standards.
• Supervise CNC VTL, CNC HTC, CNC VMC, CNC HMC, Hydro Testing, Welding, and related machining operations.
• Ensure proper tooling, inserts, fixtures and gauges availability.
• Guide operators on machining processes and resolve technical issues.
• Plan, organize, and monitor daily machining activities to achieve production targets and delivery commitments.
• Ensure timely completion of components as per dispatch schedule.
• Support dispatch team to ensure customer delivery commitments are met.
• Efficiently allocate manpower and ensure proper shift planning to meet production requirements.
• Thorough knowledge of ISO 9001:2015 and IATF 16949 Quality Management Systems.
• Monitor daily production output and implemented corrective actions to prevent production delays.
• Review and approve machine-wise production planning.
• Monitor daily, weekly, and monthly performance against approved plans, budgets, schedules, and key operating indicators.
• Strong knowledge of CNC & VMC, HMC machining operations and machine shop management.
• Hands-on experience in CNC/VMC, HMC Programming, process optimization, tooling, and cycle time improvement.
• Co-ordinate with internal customers such as Maintenance, MRP, Store, QM, Assembly, IED/ Tool Engineering to ensure process standards and timely delivery as per plan.
• Co-ordinate for third party inspection and offer valves for inspection.
• Supervised vendor machining activities to ensure quality standards. and outsourced process status.
• Complying with ISO 9001 ISO 14001 & ISO 45001 certification requirements.
• Optimize utilization of manpower, machines, materials, and other resources.
• Monitor cutting tool usage and ensure timely availability of tools to avoid production delays.
• Oversaw daily work management in the machine shop to maintain workflow. and 5S with shop team.
• Co-ordinate with internal customers such as Maintenance, MRP, Store, QM, Assembly, IED/ Tool Engineering to ensure process standards and timely delivery as per plan.
• Co-ordinate for third party inspection and offer valves for inspection.

• Set and operate CNC VMC, HMC, VTL, HTC and CNC Turning machines as per engineering drawings and process requirements.
• Load and verify CNC programs and make necessary program corrections for dimensional and process requirements.
• Perform machine setup, tool setting, workpiece setting, fixture alignment and offset setting.
• Set cutting tools, inserts, tool offsets, work offsets and machining parameters.
• Study component drawings, specifications, tolerances and machining requirements before setting the machine.
• Conducted first-off machining and inspected components with Vernier caliper, micrometer, bore gauge, height gauge and other precision measuring instruments to ensure compliance with specifications.
• Monitor critical dimensions, surface finish and tolerances during production.
• Carry out in-process inspection and make tool/offset adjustments to maintain dimensional accuracy.
• Optimised cutting parameters to enhance cycle time, extend tool life, and improve overall machining quality.
• Troubleshoot machining problems such as tool wear, vibration, chatter, dimensional variation and surface-finish issues.
• Ensure proper tool selection, coolant concentration, lubrication and machine condition before production.
• Follow SOPs, work instructions, safety procedures and quality standards.
• Promoted operational efficiency by maintaining a clean, organised machine environment through 5S practices and basic preventive maintenance.
• Coordinate with Production, Quality, Tool Room and Maintenance teams to resolve machining issues.
• Support new component development, trial machining, process proving and production stabilization.
• Maintain production records, tool-setting sheets, inspection records and process documentation.
• Achieve production targets while maintaining Safety, Quality, Delivery and Productivity (SQDP) standards.