SENTHILKUMAR S
PRODUCTION SEINOR EXECUITVE ENGINEER
Coimbatore,TN
Summary
Bachelor of Engineering graduate in Mechanical Engineering with 19+ years of hands-on CNC shop floor experience and expertise in process optimization, quality control, and customer-focused manufacturing. Skilled in macro programming for VMC/HMC machines, SOP development, and root cause analysis. Adept at building robust systems for defect prevention, complaint handling, and continuous improvement. Strong communicator with proven ability to train teams, empower problem-solving culture, and deliver customer satisfaction through reliable, zero-defect processes.
Technical mastery (CNC, quality systems, automation).Leadership resilience (entrepreneurship, team empowerment).
Business impact (customer acquisition, zero-defect culture).
Overview
20
20
years of professional experience
3
3
Languages
Work History
Manufacturing -Engineer /Machine Shop Supervisor
FAIVELEY TRANSPOT WABTEC CORPATION
12.2024 - Current
- Daily Review through PPC meeting
- Based on schedule review RM plan with purchase and follow up for timely RM delivery.
- Kanban stock plan vs actual
- Meet the customer requirement based on planning for daily, Weekly and monthly basis
- Follow the Supplier and meet daily and weekly schedule
- Follow SOP documentation, and root cause analysis inspection processes.
- Conducted rejection review meetings and prepared detailed reports for quality deviations.
- Control Plan, SPC Charts, & Audit Schedule. PDCA & SDCA
- Assisted in implementing 5S & 7S methodology across the shop floor.
- Participated in root cause analysis using Fishbone diagrams and Pareto charts.
- Collaborated with cross-functional teams to reduce defect rate by 15%.
- Root Cause Analysis (RCA)
- Step-by-Step RCA Training Plan for our Team
- 5 Whys worksheets, Fishbone, Pareto, FMEA
- Keep it interactive-ask them to share examples of recurring problems.
- QMS & Six Sigma uses to DMAIC & DMADV
- Corrective & Preventive Actions (CAPA)
- CMM, profile projectors, visual checks
- TQM Tools
- SPC
- Developed technical documentation, including standard operating procedures, work instructions, and engineering drawings to support manufacturing operations.
- Led Kaizen events focused on continuous improvement within various areas of the manufacturing environment.
- Collaborated with cross-functional teams to develop innovative solutions for complex engineering challenges.
- Trained and mentored junior engineers, fostering a culture of continuous learning and professional development within the team.
Principal Engineer PM Department
MAKINO INDIA PVT LTD.
05.2024 - 09.2024
- Process Design & Optimization: Develop and refine machining processes (HMC & VMC milling) to improve cycle times, reduce waste, and enhance precision.
- Kaizen & Lean Initiatives: Lead continuous improvement efforts like Kaizen events to rearrange workstations, streamline workflows, and reduce labour costs.
- Tooling & Equipment Strategy: Select, design, and validate tooling and fixtures for complex parts; ensure machines are utilized to their full potential.
- Quality Systems & Documentation: Implement SPC, FMEA maintain ISO/GMP compliance.
- Supplier & Vendor Collaboration: Audit suppliers, support machining and forging processes, and ensure external partners meet quality and delivery standards.
- Capital Projects & ROI Analysis: Evaluate major investments in equipment or layout changes, providing documentation on cost vs. payback.
- FANUC 2D programming.
- MACROS programming.
Senior Production Engineer
TEEKSHA INDUSTRIAL
06.2021 - 07.2024
- Prepare monthly weekly dispatch plan and follow-up with PPC for parts
- Daily follow up with vendors, and ensure pickup by following up with logistics dept
- Monitoring Work efficiency of operators and setup approval.
- Main- Tain quality and tracing production data online check sheet.
- Analyze daily rejection and take suitable counter measures to avoid recur- Rence.
- Implementing POKA YOKE system in machine & fixture to reduce or eliminate the defects.
- Implementing of various Kaizens for reducing Cycle time reduction
- Implementing of cost reduction activities.
- Managed production schedules, ensuring timely delivery of products while maintaining high quality standards.
- Performed root cause analysis and implemented corrective actions.
- Provided technical support to troubleshoot equipment issues, minimizing downtime and maintaining production targets.
- Communicated with other team members to enhance process and performance.
- Created engineering documentation for manufacturing processes, equipment specifications and change notices.
- Partnered with supply chain management to optimize inventory levels, reducing carrying costs without sacrificing operational readiness.
Development & Production Engineer
MM GEARS PVT.LTD CBE
06.2018 - 06.2021
- Prepared Production plan & ERP supply product development
- New tools Development
- Analyzing drawings, manuals, specifications, or sample part to determine dimensions and tolerances of finished workpiece.
- Designing jigs and fixtures and gauges for new development as well as for regular production.
- Identifying proper tool selection, accessories and clamping arrangements.
- Writing programming for machine code to regulate machining along the cutting path.
Setter Cum Programmer production engineer
KARMEN INTERNATIONAL PVT.LTD CBE
05.2015 - 06.2018
- Analyzing drawings, manuals, specifications, or sample part to determine dimensions and tolerances of finished workpiece.
- Identifying sequence of operations, and setup requirements.
- Designing jigs and fixtures and gauges for new development as well as for regular production.
- Identifying proper tool selection, accessories and clamping arrangements.
- Writing programming for machine code to regulate machining along the cutting path.
- Verifying conformance of finished workpiece to specifications and provided documentation.
- Taking initiative to improve & sustain 5S of machine shop.
VMC Team Leader
TARA AEROSPCES SYSTEM (P) LTD
01.2013 - 02.2015
- Prepared Production plan
- Drawing Arrangement
- Fixture Arrangement
- Tools Arrangement
- Programming Arrangement
- Inspection Report Arrangement
- Setup seat Arrangement
- Material Arrangement
HMC Setter-cum operator
FLOW LINK SYSTEAM (P) LTD
04.2010 - 12.2012
- Fixture Arrangement
- Tools Arrangement
- Programming Arrangement
- Performed preventive machine maintenance.
- Improved production efficiency by accurately setting up machinery and equipment for smooth operations.
- Resolved technical issues efficiently, minimizing disruptions to production schedules.
HMC Operator
LAKSHMI RING TRAVELLERS PRIVATE LIMITED
06.2006 - 03.2010
- Performed operating and handling operations as per the machine programming.
- Observed machine operation to detect malfunctions or out-of-tolerance machining Process, and adjusted machine controls.
- Inspects parts before and after machining to insure manufacturing to specification.
- First audit Inspection repot.
- Maintained a safe working environment by enforcing strict adherence to safety guidelines and protocols.
- Operated various types of machinery, demonstrating versatility and adaptability in diverse work environments.
Education
C.B.S.E - Science Education
C.B.S.E Govt. Senior Secondary School
Andaman, India 04.2001 -
ITI - Engineering
GKDITR,
Coimbatore, India 04.2001 -
DME - Engineering Mechanics
RVD University
Coimbatore08-2017
B.E - Engineering
INDIAN INSTITUTE OF INDUSTRY INTERACTION EDUCATION AND RESEA
Chennai, India 04.2001 -
Skills
CNC machine shop
Exposure in our line of activities – Foundry, Machine Shop, NPDs, CIPs etc
Scheduling and conducting Management Review Meetings
Centerless HMC & VMC
Team Building
Demand and Supply Planning
Capacity Planning
4M
FMEA & PFMEA
Standard PFMEA / Control plan
Equipment standards
TQM & QMS CONTROLS
8D & CAPA
ERP & SAP
Personal Protective Equipment (PPE)
R&D and PPM to support DFA/DFM activities
Team Management & Leadership
Scheduling and Conducting Internal QMS Audits
PE guidelines and WFM’s
Equipment standards
Standard PFMEA / Control plan
Coordinate with Quality, Supply Chain, and Production teams to resolve production issues and meet delivery schedules
Root Cause Analysis
Accomplishments
- Modified fixture design improvement - Based on the improvement set up changeover time has been reduced from 60 minutes to 40 minutes.
- Washing Machine fixture design change - Based on the improvement productivity increased from 600 numbers to 800 numbers by optimizing the cycle time. 20% of production increased.
- Reduced cycle time in HMC Machine - Identified reamer tool was run with no usage. Operation Skipped and cycle time reduced.
- Reduced tool cost - Earlier we have used two different tools for two operations. Based on the improvement we have used one tool for two operations and saved tool cost.
Personal Information
- Date of Birth: 13-11-1986
- Gender: MALE
- Nationality: Indian
- Marital Status: married
- ID Type: Passport
- ID Number: J397298
Father's Name
S. Sathaiah
Timeline
Manufacturing -Engineer /Machine Shop Supervisor
FAIVELEY TRANSPOT WABTEC CORPATION
12.2024 - Current
Principal Engineer PM Department
MAKINO INDIA PVT LTD.
05.2024 - 09.2024
Senior Production Engineer
TEEKSHA INDUSTRIAL
06.2021 - 07.2024
Development & Production Engineer
MM GEARS PVT.LTD CBE
06.2018 - 06.2021
Setter Cum Programmer production engineer
KARMEN INTERNATIONAL PVT.LTD CBE
05.2015 - 06.2018
VMC Team Leader
TARA AEROSPCES SYSTEM (P) LTD
01.2013 - 02.2015
HMC Setter-cum operator
FLOW LINK SYSTEAM (P) LTD
04.2010 - 12.2012
HMC Operator
LAKSHMI RING TRAVELLERS PRIVATE LIMITED
06.2006 - 03.2010
C.B.S.E - Science Education
C.B.S.E Govt. Senior Secondary School
04.2001 -
ITI - Engineering
GKDITR,
04.2001 -
B.E - Engineering
INDIAN INSTITUTE OF INDUSTRY INTERACTION EDUCATION AND RESEA
04.2001 -
DME - Engineering Mechanics
RVD University