Subramani Sundaramoorthy

Providing freelance consulting, mentoring, and skill development support to MSME Manufacturing industries in the areas of Lean Manufacturing, DMAIC, Quality Systems, Production Management, and Continuous Improvement.

• Collaborated with cross-functional teams to successfully deliver comprehensive solutions for clients.
• Evaluated client needs and expectations, establishing clear goals for each consulting engagement.
• Developed innovative strategies for clients, resulting in increased revenue and business growth.

· Conduct training programs on Lean Manufacturing, 5S, Kaizen, Visual Management, 7QC Tools, and Waste Elimination.

· Mentor shop floor teams and supervisors on productivity improvement, process discipline, and quality enhancement.

· Support industries in implementing Operational Excellence initiatives and quality improvement projects.

· Conduct process audits, product audits, and gap analysis for manufacturing systems.

· Guide organizations in implementing ISO/IATF documentation, PFMEA, Control Plans, and PPAP activities.

· Assist industries in layout improvement, material flow optimization, and cost reduction initiatives.

· Deliver awareness sessions on Industry 4.0, workplace safety, and manufacturing best practices.

· Support skill development initiatives for engineers, supervisors, and operators through practical shop-floor training.

· Successfully trained and mentored manufacturing teams across machining, fabrication, and sheet metal industries.

· Improved process awareness, employee involvement, and shop-floor discipline through structured training programs.

· Supported companies in reducing defects, improving productivity, and strengthening quality systems. Improvement programs and managing end-to-end production and quality operations.

• Basic Lean Implementation
• Forming a cluster between companies. Visiting all the companies and provide training on Basic Safety, 5S, VM, MMC, Kaizens, 7QC tools, Waste elimination, DWM.
• Also provide handholding by conducting a Gemba walk in each visit and give live demonstration in shop floor of training provided.
• Advanced Lean Implementation
• Getting application and completing enrolling formalities. Also collecting the payments from cluster companies as per agreement.
• Forming a cluster between companies. Visiting all the companies once a month and provide training on Advanced Safety,Electrical Safety, Advanced 5S, VM, MMC, Kaizens, forming QA & QC, CTQ & CTC analysis, 3M & VSM, Material Handling & Accounting, Inventory Turn Ration, Vapco, creating a VMI & DWM.
• Also provide handholding by conducting a Gemba walk in each visit and give live demonstration in shop floor of training provided.
• Identifying the bottleneck operations and improving the layout through kaizen.
• Developing Management information system.
• Giving homework’s to the company on improvement to be done and monitor the improvement month on month.
• Also conducting MRM’s with all clusters once in 3 months and culminating the program with end customer’s show casing the improvements.
• Material Flow Cost Accounting (MFCA) Implementation
• Creating awareness on material flow and identifying the quantity centers. Creating a Material flow model.
• Calculating the positive material and negative materials.
• Calculating System Cost, Energy Cost, Auxiliary material cost.
• Understanding the economic and analyze the root cause to improve.
• Improving the environment impact and economical waste.
• Also conducting MRM’s with all clusters once in 3 months and culminating the program with end customer’s show casing the improvements
• Third Party Audit
• Conducted 6 PPAP Audits & 8 Special Process Audits on Painting & Powder Coating to TVS Motor – Tier 1 Suppliers.
• The Automotive Component Manufacturers Association of India (ACMA) is a apex body representing India's Component Industry. It boasts a membership exceeding 850 manufacturers, contributing to more than 85% of the auto component industry's total turnover. It conducts Clusters and project activities to its member companies.
• Nature of Business
• Cluster & Projects
• Basic Cluster - Lean Manufacturing
• Advance Cluster - Lean Manufacturing
• Advanced 5S
• Zero Defect Quality Cluster
• Value Stream Mapping & Layout Improvement
• Material Flow Cost Accounting (MFCA)
• New Product Development Foundation Cluster
• New Product Development Design Cluster
• Zero Defect in NPD process
• Skill Development Cluster
• Low Cost Automation Cluster
• Human Resource Cluster
• Third Part Audits.
• Major Customers
• M/s. JK Fenner
• M/s. Ashok Leyland
• M/s. TML
• M/s. Bajaj Auto
• M/s. TVS Motors
• M/s. India Piston Rings
• Self-motivated, with a strong sense of personal responsibility.
• Excellent communication skills, both verbal and written.
• Proven ability to learn quickly and adapt to new situations.
• Skilled at working independently and collaboratively in a team environment.
• Worked well in a team setting, providing support and guidance.

• Production
• Absolute responsibility for entire production line from customer Schedule, RM planning (VMI / WIP) accounting, Production Planning to ASN generation. Production budgeting, JIT Inventory & tool management, Vendor management& ASN creation.
• Plasma profile cutting machine nesting, Programming, Plate Alignment and maintenance work.
• Manpower planning and allocation for optimum utilization of resources to achieve set goal. Regular interaction with Planning, Purchase, Stores and commercial dept. to ensure SCM-Supply Chain Management
• Periodically prepare, monitor and document various production records like Capacity Assessment, Production sheet, Route card, Tool life, First OFF & Last OFF, Welding Penetration test
• Quality Systems
• Absolute responsibility for entire Quality activities like Product Quality, Process Quality & System Quality.
• Understand customer needs & requirements to develop robust production set up and quality processes. Also a CFT Member for innovative solutions to the various challenges.
• Review, maintain and prepare all required documents for ISO 9001:2015 QMS, ISO 14001:2015, ISO 45001:2008, Customer Process & Product audit frequently. Conduct internal & supplier process & product audit for gaps and improvement of process as per QMS standards. Internal Audits on ISO 9001, 14001 & IATF 16949.
• Periodically monitor and maintain In-house, Supplier & Customer end PPM trend. Identy the non-confirming process and analyze the process by collected data for improvement using 7QC tools. Implementing error proofing method (POKA YOKE) to improve in process control.
• Conducts internal projects as a part of continuous improvement activity (KAIIZEN), to improve current processes quality, product quality and costs saving. Special Projects for cost savings and process improvements using Six Sigma (DMAIC).
• New Product Development procedure from enquiry to PPAP level. (Process design & MFR, First time right on sample submission, Quotations, Proto type sample, Tooled up sample, PTR, PPAP)
• Update PPAP, based on the consequent process improvement made on PF, CP, PFMEA (update RPN). Update SPQR & DCR periodically. Conduct internal audit and training on ASN, Kanban, JIT, 5S, Red Tag Campaign for eliminating wastages (MUDA, MURI, and MURA).
• To handle customer complaints and close within 7 days, Analyze and eliminate the defect using corrective action report (CAR) 8D method. Raise and follow SCAR to supplier on the defect part received. Create OPL and update PFMEA accordingly.
• Conduct Management Review meeting periodically on production, quality status and developments. Collaborate with management and line production staff to achieve best result. Training production, QA/QC staff for QMS practices and basic quality requirements.
• Manufacturing of fabricated assemblies and CNC machining components for automobile industry and general engineering industry.
• Fabricated Assemblies
• Fabricated Brake Chamber Brackets
• Spring Seats
• Shock Absorber Brackets
• SPM Outer Chassis Welding
• Sheet Metal Forming & Welding
• Casting Machining
• Brake Chamber Brackets
• Clutch Withdrawal Sleeve
• Bearing Block
• Bottom Shafts
• Steel Forging Machining
• Tracker Sockets
• Tracker Drop Arms
• Metro Train Brake Hub
• K9 Tanker Track Guide
• K9 Tanker Clamp Pair
• K9 Tanker Pin
• Rocket launcher Shell Body
• Bore Well Tool Bit
• Torsion Shaft & Pipe
• Customers
• M/s. Brakes India Limited, Chennai
• M/s. Automotive Axle Limited, Mysuru
• M/s. Axles India Limited, Chennai, Sriperumbudur
• M/s. Skanray Technologies Pvt Ltd, Mysuru
• M/s. Bhagyaa Induction, Mysuru

• Meeting With customer, Understand the requirements, Design Data Collection, Designing, Design Approval Process from customer, Drafting, Creating Bill of materials, Material Planning, Project scheduling (Using M S Project) and coordinate with manufacturing department.
• Releasing Drawing for manufacturing with GDNT and various treatments.
• Tool assembly with manufacturing team and hand over the tool to customer for tool prove out. Coordinate with customer and manufacturing team for any correction on the tool.
• Project Title: Intel Motherboard Components Dismantling & Assembling Fixture, Foxconn Service
• Project Title: Position Checking Gauge for Battery Bike Chassis. B S A Motors.
• Project Title: Bending Tool for Cycle Handle Bar, T I Cycles.
• Project Title: Wiper Gear Box Fixture, TVS LUCAS, PADI.
• Project Title: Glass & Channel Rubber Assembly Fixture, Ashai India Glass Ltd.

• Training mechanical design software's like AutoCAD 2007, Pro E 3.0, Ansys 9.0. Basics in Solid Works. Project planning software's like M S Project 2007 and Primavera P6.
• Administered periodic exams on design tools using live projects and evaluated student performance to support certification process.
• Identified slow learners and conducted specialized training sessions to enhance understanding.
• Conducted training sessions for corporate members at their offices, including Johnson & Johnson and Brakes India Ltd.
• Identify slow learners to conduct special batches and attention.
• Project Title: “Reducing the Thickness Variation in Brake Linings”
• Objective of the project was to improve the manufacturing process capability by reducing the thickness variation of Brake Liner used for Heavy Commercial Vehicles.
• Applied 7 QC steps and 7QC Tools to identify the possible root cause (Cause & Effect diagram), validated the identified root cause and evaluated the implemented corrective action Control Chart (Cp&Cpk Study).