SHANMUGASUNDARAM K
Operations Manager
Coimbatore
Summary
A visionary and results-oriented Operations Manager with over 27 years of experience within the manufacturing sector. Expert in orchestrating end-to-end production planning, shopfloor management, and process optimization for high-capacity industrial environments. Proven history of leading large, cross-functional teams to deliver consistent improvements in productivity, quality, and cost control. Specialized in bridging the gap between high-level strategic consultancy (McKinsey, Japanese Lean Experts) and shopfloor execution. Adept at implementing Lean Manufacturing, TPM, and Six Sigma methodologies to drive operational excellence and significantly reduce waste.
Overview
28
28
years of professional experience
1
1
Language
Work History
Senior Manager
LMW LIMITED
01.2023 - Current
- Directly manage end-to-end operations for Assembly and Machine shop production lines.
- Led a diverse workforce of 250+ personnel, maintaining a consistent 95% on-time delivery record.
- Successfully improved machine availability from 82% to 95% through the rigorous implementation of TPM initiatives.
- Achieved a 21% reduction in cycle time by deploying line balancing techniques and systematic bottleneck elimination.
- Introduced a dashboard-based daily performance tracking system to facilitate shift-wise reporting and rapid escalation of production issues.
- Strategic Cost Reduction & Consulting
- LAMP Project (McKinsey): Coordinate LAMP project implementation with McKinsey consultants, focusing on review-driven action planning and cross-functional team (CFT) initiatives.
- Financial Impact: Spearheaded multiple Gemba workshops across machining and sub-assemblies, generating 227 Crores in annualized savings through procurement and design levers.
- Innovation: Championed the introduction of Low-Cost Automation to enhance process efficiency and reduce manual intervention.
- Quality & Supply Chain Synergy
- Collaborated with SCM and Quality teams to achieve a 70% reduction in customer complaints over a 12-month period.
- Ensure 100% feedback implementation for project ideas with GS clearance by coordinating with R&D, Quality, and SCM.
- Drive continuous improvement in Cost per Machine (CPM) across all division products.
- Progressive leadership roles focused on Shopfloor Management, Production Planning, and Control (PPC).
- Experience in Inventory & Material Flow Optimization and Quality Control (ISO).
- Expertise in managing Safety, Compliance, and EHS Standards in heavy manufacturing environments.
Assistant Manager to Manager
LMW LIMITED
01.2013 - 01.2023
- Mass production unit- Textile spindle manufacturing-
- Reduced cycle time by 21% through implementation of line balancing and bottleneck elimination by VSM
- Led TPM initiative that improved machine availability from 82% to 95%.
- Coordinated with SCM and Quality teams to reduce customer complaints by 70% over 12 months.
- Introduced dashboard-based daily performance tracking system for shift-wise reporting and quick escalation.
- Co ordinating ACME process implementation with Japan consultant Mr Takavo san for process improvements 30% assembly time reduction and introducing Low-cost automation.
Engineer to Senior Engineer
LMW LIMITED
01.2004 - 01.2013
- Led common machine shops include CNC lathes, Turn mill and VMC and Conventional machines. Handling discreates jobs and maintains the delivery commitment ensures the Daily roll out of machines in smooth manners.
- Eliminate conventional machines and improve the operational efficiency of by introducing CNC machines and implementing Turn mill centers through VSM in cylindrical and Roller section.
Assistant Engineer
LMW LIMITED
01.1998 - 01.2004
- Led Assembly section and general machines. Prove out the NPD parts and establish production process all NPD parts with new tooling and fixture arrangements.
Education
Master of Industrial Engineering - undefined
Anna University
CBE01-2016
MBA - Business Management (Production)
Madurai Kamaraj University
01-2013
B.E. - Mechanical Engineering
Coimbatore Institute of Technology
CBE01-2009
Skills
Systems: Oracle ERP/MRP, Performance Dashboards
Methodologies: Six Sigma, TPM, Lean Manufacturing, 5S, Kaizen
Awards
QCFI - Par Excellence Award winner for QCC - Reduce the process rejections in 2022, LWM - Manufacturing Champion award winner in 2023, CII - Gold award winner for Best Kaizen for Productivity improvement in 2024
CORE COMPETENCIES
- Operational Leadership: Production & Shopfloor Management, Capacity Planning & Line Balancing.
- Lean Transformation: 5S, Kaizen, Value Stream Mapping (VSM), and SMED.
- Asset Management: OEE (Overall Equipment Effectiveness) Improvement and TPM Initiative Leadership.
- Strategic Projects: LAMP Project Execution, ACME (Manufacturing Excellence Program) Process Implementation, and Low-Cost Automation (LCA).
- Cost & Quality: Cost per Machine (CPM) Reduction, ISO Quality Control, and EHS Standards.
- Systems: Oracle ERP/MRP Systems and Dashboard-based performance tracking.
PROFESSIONAL AFFILIATIONS & PROJECTS
- Key contributor to CFT (Cross-Functional Team) initiative in COST Reduction projects.
- Leader of workshop idea implementation aligned to corporate strategic goals.
- Expert in Gemba Workshop facilitation and idea generation
- Manufacturing Excellence projects
Timeline
Senior Manager
LMW LIMITED
01.2023 - Current
Assistant Manager to Manager
LMW LIMITED
01.2013 - 01.2023
Engineer to Senior Engineer
LMW LIMITED
01.2004 - 01.2013
Assistant Engineer
LMW LIMITED
01.1998 - 01.2004
Master of Industrial Engineering - undefined
Anna University
MBA - Business Management (Production)
Madurai Kamaraj University
B.E. - Mechanical Engineering
Coimbatore Institute of Technology