SANTHOSHKUMAR VIJAYAN
Ahmedabad
Summary
Quality Manager with extensive experience at Harrow Security Vehicles LLC, specializing in production management and quality assurance. Proven expertise in cycle time optimization and implementing continuous improvement strategies. Successfully drives safety initiatives and cost control measures while enhancing team collaboration to boost productivity and operational excellence.
Overview
25
25
years of professional experience
Work History
Quality Manager
Harrow Security Vehicles LLC
Dubai
02.2022 - Current
- Leading identification, resolution, and closure of Final Assembly Engineering (FAE) feasibility issues
- Supporting identification, resolution, and closure of all identified product, process and tooling issues
- Interfacing with cross-functional activities and involved in work group such as kaizen, Cost Saving, Projects, Energy Conservation & Maintaining 5S Demand and ensuring the Spare Management System in FTPTM
- Maintaining production efficiency to improve Cycle time and reducing downtime for all shop floor process like Spot welding, Hemming (Manual, Press, Robot and Table Top), MIG welding, Door setting Process & Metal finish process
- Preparing and updating DFMEA & PFMEA for all process and maintaining cycle time by achieving daily and yearly target of the production schedule
- Promoting Safety, Quality, Kaizen, Cost saving, Energy conservation and Housekeeping, by Motivating and Encouraging the group to meet responsibilities to achieve management Policy Deployment targets & NWG, etc.
- Imparting training to the team members on the job and assist supervision in troubleshooting.
- Handling SHARP (Safety and Health Assessment Review Process) activities to improve shop floor safety
- Addressing and resolving the design related Safety issues during design reviews
- Initiating WSR after installation and closing all open points through line builder
- Taking immediate actions for GFCPA, CAL & FPA issues to protect customers
- Resolving dimensional issues during design review and following the same during upcoming build events to ensure quality
- Updating AIMS and follow up with PD & Other regional teams to close the same.
- Participating in Layout Preparation for New Model Program and Ensuring Lean concept during design review
- Allocating the manpower based on the line JPH
- Updating all Preventive Maintenance activities and Breakdown Maintenance in TEM (Total Equipment Management) software
Production Associate for Stamping Department
Ford India Ltd.
Chennai
06.2000 - 03.2001
- Delivered Manufacturing Quality Operating System requirements for specific subsystems.
- Ensured timely delivery of vehicles with high-quality assurance standards.
- Inspected incoming and outgoing vehicle conditions, updating details in cloud-based ERP system.
- Conducted all jobs according to work orders for consistency and compliance.
- Responded promptly to customer concerns, performing root cause analysis and implementing action plans.
- Managed labor availability according to production plan and conducted training for quality output.
- Collaborated with Product Development team to estimate facility costs, enhance quality, and minimize labor needs.
- Developed Failure Mode Effective Analysis plan and documentation for new model programs.
Education
Post Graduate Program - Artificial Intelligence for Leader
The University of Texas at Austin
Austin, Texas, USA06.2020
B.E. - Mechanical Engineering
AIMTE, Delhi
Delhi09.2013
Diploma - Mechanical Engineering
AIMTE-Delhi
Delhi04.2009
Skills
- Production management
- Quality assurance
- Cycle time optimization
- Project management
- Shop floor safety and kaizen
- Cost control
- Productivity enhancement
- PMEA methodologies
- Continuous improvement strategies
- Energy conservation practices
- Preventive and breakdown maintenance
- Workforce management
Languages
English, Hindi, Tamil, Malayalam, Telugu
Projects
Title: “Lean Manufacturing on IKON Closure” Description: Mass production layout re-designed and inventory reduced from 20 No’s to 1No’s. Waste eliminated and HPV improved from 4.5hrs to 60mins.Cycle time reduced from 4.8mins to 3.6mins per job., Title: “JPH improvement on Fiesta closures hemming press line” Description: Old layout redesigned, new mobile trolleys designed for eliminate operator waiting time, PLC modification done for improves output on press line and training given to operator for improve cycle time., Title: “6 Sigma Green Belt Project (Reduction of Hemming Issues in Closures Line at SVAP)” Description: To avoid all existing issues in new model program faced by Lead Plants, to improve Safety, Quality, Delivery and Cost in SVAP
Accomplishments
- Received Spot Recognition Award from Top Management for successful installation of new automation layout and implementation of equipment’s in shop floor for New Model Program
- Developed concept for Lean Layouts & buy off done in Wooshin Pvt. Ltd., Korea and commissioned the same in the Ford India Plant
- Successfully done Main line conveyor logic error proofing buy-off done in Vinar Pvt. Ltd.
- Done VDL equipment buy off in Web India Pvt. Ltd.
- Handled SHARP (Safety Health Assessment Review Process) activities and reduced LTC (Loss Time Case – Accidents) to company significantly
- Developed local supplier for completing the projects on time & handled them for effectiveness service support
- Saved Power & Water to the environment deployments
- Introduced Lean manufacturing system to reduce the lead – time of the product flow in the line itself
- Optimized task in PM based on equipment history data and man Hrs optimized respectively
Awards
Asia Pacific Recognition Award (APA) for 4 times, 1st prize for Best Improvement (Kaizen) - 5 times, 1st prize for cost saving suggestion - 2 times, 2nd prize for best project implementation - 2 times, Participation award for best improvements - 23 times, Participation award for New Model Launch - 2 times
Training
- 35 days in EDAG project development plant in Gurgaon (New Delhi) – 2005.
- 48 days in ABB robotics, Bangalore (Karnataka) for Figo closures line implementation-2008.
- 33 days in Auto Alliance Thailand for New Fiesta readiness-2010
- 67 days in Hirotec India Ltd, Coimbatore, Tamil Nadu for Eco Sport readiness – 2012
- 15 days in Changan Ford Mazda (CFMA), Chongqing, China for Ecosport readiness – 2012.
- 40 days in Hirotec India Ltd, Coimbatore, Tamil Nadu for New Model Program Design review for Closures Line - 2013
- 30 days in Hirotec Japan, Hiroshima, Japan for New Model Program VTTO event - 2014
EQUIPMENT KNOWLEDGE
- Resistance welding m/c – Xmeco, Mechonic & Obara.
- Welding timer – British Federal, Mechlonic & Obara.
- Robotics – ABB
- MIG welding m/c – Ador.
- Stud welding m/c – Tucker GMBH
- Manual fixtures, Pneumatics welding fixture clamps – Tunker
- Hydraulic Clinching Machine – Eckold.
- Hot & Cold Melt Sealers – Graco USA.
- Hydraulic press (500 ton) – ISGEC.
- Hoist & Jib cranes – Demag.
- Spring balancer – Hendo & Atlas Capco
- WINCC & HMI Controllers
- Projection Welding M/C –Serra
- EMS-Hoist
- PLC controller Advance with P-Net configuration
- Win Punching M/C – Telesis
Technical Qualification
- LAMP - Training in analysis & Designing datum points in fixtures
- ABB - Training in Robot Roller Hemming
- Hirotec - Training in Table Top Hemming
- EDAG - Training in Press Hemming
Software Skills
MS Project, Office, Windows2007, MS Front Page, FMEA (Byte work) TEM & QAD System, PDV or Team Center, WERS, GSPAS, AIMS, E2KS
Clients Handled
- Figo Line Builder: Wooshin System Co & Obara Korea
- Global Fiesta Line Builder: Wooshin System Co & Obara Korea
- Robotics: ABB (India)
- Conveyor: Vinar
- VDL: Web India
- Fiesta Line builder: Edag
- Ecosport Line Builder: Wooshin System. Co
- Ecosport Line Builder: Hirotec India Ltd.
- New Model Program: Hirotec India Ltd.
- New Model Program: Hirotec Japan
Timeline
Quality Manager
Harrow Security Vehicles LLC
02.2022 - Current
Production Associate for Stamping Department
Ford India Ltd.
06.2000 - 03.2001
Post Graduate Program - Artificial Intelligence for Leader
The University of Texas at Austin
B.E. - Mechanical Engineering
AIMTE, Delhi
Diploma - Mechanical Engineering
AIMTE-Delhi
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