Open To Work
R SURAJ KUMAR
Sulur, Coimbatore
Work Preference
Summary
Seasoned Plant Head with comprehensive experience in overseeing plant operations, including production, quality control, maintenance and scheduling. Strong leadership skills coupled with an ability to optimize plant performance and productivity. Proven capability in process improvement initiatives that enhance operational efficiency. Demonstrated success in fostering a safety culture across teams to ensure compliance with industry regulations.
Overview
19
19
years of professional experience
Work History
PLANT HEAD - OPERATIONS
MESURA NIRMAL GAS CONTROLS PRIVATE LIMITED
VADODARA
05.2024 - 07.2026
- Coordinated production planning to meet customer demands efficiently.
- Implemented maintenance schedules for equipment and machinery.
- Managed team performance, ensuring adherence to safety protocols.
- Monitored inventory levels and ordered supplies as needed.
- Fostered a collaborative work environment to enhance team communication.
- Ensured compliance with all applicable regulations related to health, safety and environmental protection.
- Created systems to track inventory levels, orders and shipments from suppliers to customers.
- Maintained budgetary responsibility for capital expenditures, operating expenses and labor costs.
- Directed and managed the daily operations of a plant, including production, maintenance, quality control, logistics and safety activities.
- Investigated customer complaints regarding product quality or delivery delays.
- Established safety protocols designed to protect workers from hazardous conditions in the workplace.
- Reviewed audit reports to ensure that all departmental goals were being met or exceeded.
- Developed plant performance metrics to measure key performance indicators such as throughput, efficiency and cost management.
- Managed relationships with external stakeholders such as local government officials, regulatory agencies or community organizations.
- Performed root cause analysis on issues identified during routine inspections or audits.
- Lead teams in the development of new processes and procedures for improved operational efficiency.
- Implemented Lean Manufacturing principles throughout the plant to reduce waste and improve overall productivity.
- Collaborated with other departments within the organization on projects related to process improvements.
- Identified areas of potential cost savings through process optimization initiatives.
- Developed strategic plans for long-term objectives related to growth targets or sustainability initiatives.
- Coordinated efforts between engineering teams working on new product launches or process modifications.
- Analyzed data from multiple sources to identify opportunities for improvement in production processes.
- Negotiated contracts with vendors for materials needed by the plant.
- Developed strategic programs and devised key plans that affected the direction of the business.
- Eliminated materials waste and unnecessary labor hours to reduce costs.
- Adjusted and improved processes to maximize efficiency.
- Supported departments in successfully utilizing available labor, materials and equipment resources for production.
- Promoted high-quality daily production by enforcing product standards and monitoring level of quality.
- Coordinated maintenance strategy for equipment, including predictive and preventive measures.
- Planned, directed and coordinated operations for production, machinery and processing within company policies and procedures.
- Oversaw employees and related programs to maximize team productivity and facility output.
- Gave direction and leadership to all levels of employees and managers.
- Analyzed production data to identify trends and areas for improvement.
- Improved workflow processes to maximize efficiency and enhance operations.
- Improved efficiency by minimizing downtime.
- Oversaw production budget and approved expenditures to direct spending.
- Liaised between senior plant management and line-level supervision to maintain open communications.
- Strategized long-term business needs and applied customer feedback for process improvements.
Deputy Manager - New Product Development
Nirmal Industrial Controls Private Limited
Mumbai
08.2023 - 04.2024
- Lead development of self-acting pressure control valves for various applications, including pressure relief and altitude control.
- Oversaw development of more than 10 new products annually while managing project timelines.
- Coordinated budgeting efforts with sales teams to optimize product costs.
- Managed project execution post-design release, ensuring supplier approval for tooling and components.
- Executed pilot lots alongside production teams, facilitating smooth transitions of up to 100 units per product group.
- Evaluated suppliers to enhance cost controls and operational efficiency.
- Implemented quality control measures to maintain product standards.
- Streamlined communication channels to eliminate bottlenecks and improve management interactions.
- Prepared and presented annual budgets, maintaining strict controls to prevent overages.
- Coordinated with other departments to ensure smooth functioning of activities.
- Delegated work to staff, setting priorities and goals.
- Reviewed completed work to verify consistency, quality, and conformance.
- Proposed or approved modifications to project plans.
Deputy Manager -New Product Development
McWane India Private Limited
Coimbatore
02.2015 - 08.2023
- Leading Manufacturer of industrial valves which is used for potable water service application.
- Resilient seal Gate valve (RSGV), Resilient seal check valve (RSCV), Hydrants, Air release valves, Double eccentric butterfly valves, concentric butterfly valves ,UL/FM RSGV,ARV, SEWAGE ARV. Control valves (Pressure reducing, Pressure relief, Pressure sustaining, Altitude control, Flow control, Solenoid operated, Pressure surge control valves).
- Preparation of Project funnels every year based on the sales/market/design requirements.
- Reviewed product development budgets, expenditures and research
- Eliminated functional bottlenecks by streamlining communication channels between management and employees.
- Maintained relationships with material vendors to lower costs and diversify capabilities.
- Developed and initiated projects, managed costs and monitored performance.
- Met project deadlines without sacrificing build quality or workplace safety.
- Accelerated progress by continually reviewing performance, budgets and project timelines.
- Identified plans and resources required to meet project goals and objectives.
- Working on the Costing for the complete product and getting budgetary approval from management to start the development activities based on priorities
- Working on the forecasted budgetary approvals for the investment for any machinery, test rig, special purpose machinery based on the project funnel
- Review the feasibility for the New Products and Prepare the RFQ's with Quality, delivery, Cost and identifying the Supplier’s as per the Our Supplier Audit Process
- Prepare the New Product Projects scheduling and from Pattern developments to Product handover to Production
- Responsibility for the New Product developments and Complete BOM Parts developments as per the target Cost
- Responsible to develop the New fixtures and testing accessories for the New Products and existing Products for the Productivity Improvements
- Responsible of development of samples and its pilot lot until handover to production upto 200 nos for each model.
- Responsible to Prepare the SOP for the Machining operations and Complete Valve assembly to Testing Process
- Responsible for the Product cost working and review the feasibility to meet the Target cost
- Introduced new methods, practices and systems to reduce turnaround time.
- Evaluated suppliers to maintain cost controls and improve operations
- Coordinate with the Supplier to meet the OTD 95% for the Machined and Bough outs.
- Functioned as point of contact for project administrators and managers focused on timely and successful completion of full life cycles of assigned projects.
- Maintained, documented and presented progress reports to leaders
- ISO Products and AWWA (UL/FM) Products Testing Special Testing
- AWWA Fitting Product design and tooling design
- To execute the testing projects /tasks of the Product Testing/Validation during and after development
- Testing of ARV Double Chamber, ARV Single Chamber, ARV ISO RSGV, ARV AWWA RSGV (UL/FM), ARV ISO SCV, ARV ISO DEBFV, Control Valves.
- Executing Product certifications for the complete range of products by coordinating with TPI agency like UL/FM, CE, API & BVQI inspection agency
- Assistance in Prepare testing schedule and execute as per the schedule
- Making the parts and accessories required for testing & Validation
- Maintaining testing accessories and measurement
- Calibration of Test rig and Measuring instruments
- Assistance in Preparation of Test Reports as per the test output
- Coordinate and plan with Design, Quality, and planning and to ensure the availability of testing accessories for any NPD valves
- Coordinate with design and quality and to plan for new test machines based upon the requirements and to follow-up with vendor for its readiness till erection and commissioning and successful trial test
- Responsible to follow and maintain EHS in the workspace.
Sr.Engineer – QA/QC
Cesare Bonetti India Private limited
Vapi
12.2011 - 10.2014
- QA - Leading Manufacturer of High-Class Rating Valves to Various Projects orders (Waaree Group) (Gate, Globe, Check, Piston, Ball, level Gauges)
- Procurement of all measuring instruments and machines required related to testing and inspection
- Section Quality In charge and Responsible for incoming, in process, testing & final inspection activities including inspection of Fasteners of different grades as per standard
- Reviewing & Approving of MTC’s & relevant reports pertains to components/Raw material for it correctness as per codes and standards
- Section In charge for Sample approval of Forging/Casting/Pattern/Plaster cast/Heat treatment
- (Visiting to vendor premises for inspection all over India)
- Directly handled various auditors, Customers and IBR
- Project orders QA/QC coordinator, approval authority of ITPs and special testing procedures authority
- Preparing all SOP’s & Work Instruction related to shop floor activities
- Preparing WPS & PQR as per ASME code and get it approved by TPI agency
- Providing technical support for project order execution
- Responsible for preparation of various testing procedures such as pressure testing, cryogenic testing, hydrogen testing, Low temperature testing, fugitive emission testing etc
- Co-ordination and getting inspection clearance of product from External Inspection agency
- (IBR, NPCIL,EIL,NTPC,PDIL,BVIS,TUV,DNV,Lloyds,TPL,SGS,MOODY etc.)Responsible for special testing like Helium leak testing, Fugitive Emission, Low temperature / Cryogenic testing
- Responsible for NDT activities – MT, PT, UT, RT & LT
- Responsible for In process & Final welding inspection
- Very good knowledge in ASTM, ASME, EN, API, NACE & MSS standards
- Having good leadership in involving team members for inspection activities and implementation of new ideas
- Ensuring all activities are in line with requirements of ISO 9000 for quality system and working for Quality objectives and management information network and periodic monitoring of all QC checks / audits through system monitoring chart
- Responsible for Final painting inspection according to customer requirement
- Good Knowledge in Indian Boiler Regulations
- Responsible for vendor audit program / vendor quality improvement
- Vendor Evaluation and rating using Statistical Quality Tools
- Implementation of 7 QC tools in various inspection activities.
Engineer -QC
AUDCO INDIA LIMITED
Chennai
06.2007 - 12.2011
- Leading Manufacturer of High Class Rating Valves to Various Projects orders (F&S Gold award winner, ISO 9000 / 14001 Company) collaborated with Flowserve Flow control (FFC) Ltd, United Kingdom (Gate,Globe,Check – Cast & Forged, High pressure GGC, Plug valves), Worked as a team member in the green field project and got IMS certified by Lloyds registers
- (ISO 9001:2008, ISO 14001, and OHAS 18001)
- Section Quality In charge and Responsible for incoming, in process, testing & final inspection activities including inspection of trims & fasteners of different grades as per standard
- Section In charge for Sample approval of Forging/Casting/Pattern/Plaster cast/Heat treatment
- (Visiting to vendor premises for inspection all over India)
- Directly handled various auditors, Customers and IBR
- Project orders QA/QC coordinator, approval authority of ITPs and special testing procedures authority
- Providing technical support for project order execution
- Responsible for preparation of various testing procedures such as pressure testing, cryogenic testing, hydrogen testing, Low temperature testing, fugitive emission testing etc
- Co-ordination and getting inspection clearance of product from External Inspection agency
- (IBR, NPCIL, EIL, NTPC,PDIL,BVIS,TUV,DNV,Lloyds,TPL,SGS,MOODY etc.)
- Responsible for special testing like Helium leak testing, Fugitive Emission, Low temperature / Cryogenic testing
- Responsible for NDT activities – MT, PT, UT, RT& LT
- Responsible for In process & Final welding inspection
- Very good knowledge in ASTM, ASME, EN, BS, DN, API, NACE & MSS standards
- Having good leadership in involving team members for inspection activities and implementation of new ideas
- Ensuring all activities are in line with requirements of ISO 9000 for quality system and working for Quality objectives and management information network and periodic monitoring of all QC checks / audits through system monitoring chart
- Responsible for Final painting inspection according to customer requirement
- Good Knowledge in Indian Boiler Regulations
- Central Flaw less Start-up initiative (FSI) coordinator to entire organization.
- Responsible for vendor audit / vendor quality improvement
- Vendor Evaluation and rating using Statistical Quality Tools
- Implementation of 7 QC tools in various inspection activities
Education
Bachelor of Engineering - Mechanical
Pacific Institute of Engineering And Management
New Delhi01.2011
Diploma - Mechanical Engg
Panimalar Polytechnic College
Chennai, TN01.2007
HSC -
Dharam Hinduja Matriculation Hr. Sec.School
Chennai, TN01.2005
Skills
- Problem solving
- Production planning
- Safety compliance
- Lean manufacturing
- Budget management
- Project execution
- Supply chain management
- Cost optimization
- Team leadership
- Vendor negotiation
- Data analysis
- Effective communication
- Operations management
- Production scheduling
- Teamwork
- Critical thinking
- Communication skills
- Leadership
- Management
- Interpersonal skills
- Quality control
- Process improvement
- Inventory management
- Health and safety compliance
- ISO compliance
- Cost reduction
- Plant and warehouse operations
Accomplishments
- Thorough knowledge in special testing – Optical spectrometer/X-ray analyzer (Niton XL2 gold latest machine, Innox (used to check the base material of casting, forgings, bars, etc.)
- Certified PMI inspector from TII Techno Instruments, Pune
- Basic knowledge of FARO laser scanner arm to inspect all kinds of geometry of the job with 2D & 3D
- Thorough knowledge of SAP R/3 quality module and Microsoft Dynamics AX
- Thorough knowledge in all kinds of instruments and machines related to inspection activities
- Training program on 7 QC tools, 5 Why analysis, 8D analysis, etc.
- Training on Advanced Excel and MS Visio software
ACHIEVEMENTS:
- Reducing the LOFT (Leak on first time) report from 35% to 5%
- Improvements in documentation
- Best Problem-Solving Team in Final Inspection Area
- Reducing customer complaints from 12% to 2% by implementing PDI and checklists
- Outsourcing of various activities
- Reduction of defects level at supplier end up to 20% from the current level
- Self-certification of BOF suppliers
- Worked as department team leader
- On deputation, visited the DUBAI office to train our sales employees about our product and its application
- Visited (DEWA) Dubai Electricity and Water Authority office, Petronas, and major oil and gas EPC-related offices and gave product presentations
- Taken a new order for ball valves from Petrofac Malaysia within 26 days of my Dubai visit (Cesare Bonetti India Private Limited)
- On McWane - visited Italy Acmo control valve manufacturing unit to understand, study, and establish the facility for control valve testing in Coimbatore plant with a fully automated facility with the help of local vendors and the latest equipment that complies with NABL certification.
Hobbies and Interests
WATCHING MOVIES
WATCHING CARTOON
PLAYING CARDS
LISTENING MUSIC
Personal Information
- PERSONAL DETAILS
- FATHER’S NAME : Mr. T.RAJAN
- DATE OF BIRTH : 26.11.1987
- AGE : 38
- GENDER : MALE
- MARTIAL STATUS : MARRIED
- PASSPORT NO : J7406141
Languages
- TAMIL
- MALAYALAM
- ENGLISH
- HINDI
Software
D365 Ax
MS OFFICE
SAP R3
WINDCHILL
EPDM
SHAREPOINT
MICROSOFT D365
Timeline
PLANT HEAD - OPERATIONS
MESURA NIRMAL GAS CONTROLS PRIVATE LIMITED
05.2024 - 07.2026
Deputy Manager - New Product Development
Nirmal Industrial Controls Private Limited
08.2023 - 04.2024
Deputy Manager -New Product Development
McWane India Private Limited
02.2015 - 08.2023
Sr.Engineer – QA/QC
Cesare Bonetti India Private limited
12.2011 - 10.2014
Engineer -QC
AUDCO INDIA LIMITED
06.2007 - 12.2011
Bachelor of Engineering - Mechanical
Pacific Institute of Engineering And Management
Diploma - Mechanical Engg
Panimalar Polytechnic College
HSC -
Dharam Hinduja Matriculation Hr. Sec.School