Summary
Overview
Work History
Education
Skills
Additional Information
Area Of Strength
Personal Information
Timeline
Generic
Sivakumar K

Sivakumar K

Chennai,TN

Summary

Dynamic and results-driven professional with 27 years of extensive experience in plant operations, production, quality, and project management.

Seeking a leadership role as GM/Operation Head/COO to leverage my expertise in production, quality, projects, and new product development to drive organizational success.

Proven track record in leading cross-functional teams, driving lean initiatives, and enhancing operational efficiency to achieve significant cost savings and operational improvements.

Overview

27
27
years of professional experience

Work History

AGM - Head Production

TIDC India Limited
10.2006 - Current
  • Experience: 27 years in production, quality, greenfield projects, lean initiatives, ESG, digitization, Capex, NPD, and marketing
  • Expertise / Technical Skills: Plant operations, stamping, soft and hard machining, heat treatment, grinding, welding, finishing processes, moulding, inspection automation, assemblies and lean manufacturing
  • Leadership: Led a cross-functional team of 7 direct and 55 indirect reporters, managing entire plant operations
  • Leadership Skills: Team leadership, strategic planning, project management, conflict resolution, adaptability
  • Lean Manufacturing: Implemented SMED, process elimination, availability rate improvement, performance improvement, visual management
  • Vendor Development: Strong ability to deal with OEMs and suppliers, ensuring quality and cost standards
  • Customer Satisfaction: Improved working capital from 39 days to 21 days, enhancing OTD and customer satisfaction
  • Software Proficiency: MS Office, MS Project


Accomplishments :

  • Improved operational efficiency by 13%, resulting in cost savings of ₹2.82 Cr in 2023-24 and ₹1.81 Cr in 2022-23
  • Boosted OEE in fine blanking presses and grinding machines, leading to increased machine uptime and productivity
  • Optimized tool changeover time from 34 minutes to just 9 minutes using SMED techniques, significantly enhancing production efficiency
  • Tripled production performance from 3 to 9 units per minute by implementing an innovative pick and place method
  • Extended Mean Time Between Failures (MTBF) from 1500 to 12000 strokes per loading, resulting in reduced downtime and maintenance costs
  • Achieved 97% sample submission adherence with first-time-right quality, ensuring high customer satisfaction and repeat business
  • Directed a brownfield project with an investment of ₹90 Cr, increasing turnover by 14
  • Improved working capital from 39 days to 21 days, enhancing OTD and customer satisfaction

Team Member - Product Development

Saint-Gobain Glass India Limited
11.2005 - 10.2006
  • Led a team of 4 in product development, successfully developing windshield, tempered, and Bakelite glasses for Hyundai

Sr Engineer – R&D

Adeep Locks Limited
09.2003 - 11.2005
  • Reduced product development cycle time from 1 year to 7 months
  • Standardized shut height, stroke length, and strip width for all types of progressive tools
  • Implemented SMED to produce multiple types of lock plates with a single progressive press tool, achieving value engineering gains of ₹10 lakhs per annum

Product Development Engineer

ESSAE EXCEL (P) LTD & INTEGRATED ENGINEERING (P) LTD
05.1999 - 09.2003
  • Designed and developed welded sheet metal assemblies for 2-wheeler applications, including front fork assemblies, stands, footrests, body frames, and swing arm assemblies

Education

B.E. - Mechanical Engineering

Bharath Institute of Science & Technology
01.1998

Middle Management Development Program -

TI Edge

Lean KPO Training -

Shingijutsu Consulting
Bellevue, Washington

Skills

  • Operational Management of Plant Systems
  • Precision Stamping / Fine Blanking / Conventional
  • Soft and Hard Machining Expertise
  • Heat Treatment Techniques
  • Metal Grinding Expertise
  • Welding Techniques Proficiency
  • Surface Finishing processes
  • Moulding Expertise
  • Automation
  • Component Assembly Expertise
  • Lean Production Techniques
  • Product Development
  • Systematic Process Development
  • Automobile Component Development
  • Raw Material Evaluation
  • Supplier Evaluation
  • Tool room management

Additional Information

Core Competencies

Product Enhancement:

  • Expertise in product and process design & development of automobile parts using CATIA V5, Pro-E, and AutoCAD.
  • Extensive experience in designing and developing components for both 4-wheelers (e.g., seats, safety assemblies, latches) and 2-wheelers (e.g., front fork assemblies, stands, footrests, body frames).
  • Skilled in selecting raw materials, heat treatment processes, and surface finish coatings for various products and assemblies.
  • Proficient in supplier assessment and vendor selection for outsourcing assemblies and parts.

Process Enhancement:

  • Well-versed in press shop operations, stamping, fine blanking, and tool room management.
  • Experienced in conventional machining processes (e.g., lathe, drilling, milling, EDM, WEDM, VMC, HMC, CNC lathe).
  • Proficient in various welding processes (e.g., TIG, MIG, seam welding, plasma arc, spot welding).

Team Management:

  • Skilled in directing, leading, and motivating team members, providing continuous on-the-job training to achieve higher output in product and process development.
  • Experienced in appraising team performance, providing constructive feedback, and resolving interpersonal issues to work towards common organizational goals.

Area Of Strength

Quick Adaptability to New Challenging Roles:

  • · Demonstrated ability to quickly adapt to new and challenging roles, consistently seeking innovative ideas to improve processes. Extensive experience in various roles such as Marketing, Tool Design, New Product Development, Production, Project Management, and Lean Initiatives, providing a broad expertise and confidence to excel in new challenges.

People Development Skills:

  • · Proficient in training and developing second-level personnel across all levels, ensuring smooth transitions during internal transfers or resignations. Effective in articulating company goals to subordinates and peers, fostering a positive and productive work environment.

Decision-Making Skills:

  • · Strong ability to listen and understand requirements in detail, considering short-term and long-term plans, as well as associated risks, to make wise decisions even under pressure.

Personal Information

Date of Birth: 06/03/76

Timeline

AGM - Head Production

TIDC India Limited
10.2006 - Current

Team Member - Product Development

Saint-Gobain Glass India Limited
11.2005 - 10.2006

Sr Engineer – R&D

Adeep Locks Limited
09.2003 - 11.2005

Product Development Engineer

ESSAE EXCEL (P) LTD & INTEGRATED ENGINEERING (P) LTD
05.1999 - 09.2003

Middle Management Development Program -

TI Edge

Lean KPO Training -

Shingijutsu Consulting

B.E. - Mechanical Engineering

Bharath Institute of Science & Technology
Sivakumar K