Gangatharan

Enterprising leader & planner with a strong record of contributions in streamlining operations, invigorating businesses, heightening productivity, systems & procedures. Offering over 23 years of experience in Plant Operations & all engineering functions and also managing the complete Maintenance Entailing Planning, Resource Utilization, Corporate function, Plant Merging & Manpower Management. A Principle Executive ‘Point of Contact’ for the team with responsibility of providing overall leadership and direction for six sigma black belt ways of approach all department and plant operations to continuously improve results in safety, quality, service, budget and cost performance.

Experience in directing the entire gamut of Manufacturing Operations (Production Planning, Quality Control) with key focus on top-line and bottom-line profitability by ensuring optimal utilization of resources. Responsible for the design, implementation of manufacturing processes, equipment, plant and ensuring continual improvement related to process, cost, production and overall quality of the products. Excellent track record of setting-up plants from scratch and turning around performance of underperforming production units into high performing units and on time implementation of projects under cost parameters.

Resourceful in deploying various methodologies to analyze various scientific processes, recommending modifications to minimize escalations, reduce rejection, realize operational efficiencies, control variability, costs & reduce cycle-time. Gained knowledge of the procedures involved in ordering, receiving, storing and delivering stocks of tools & fixtures. Used methodical quality systems, productivity improvements, technological and leadership development of personnel, compliance of statutory regulations and QM.

Awarded with Distinction Award for improving Productivity by group Kaizen Activity held on 2018 &2019. Received TPM Excellence Award audit KK Pillar Head in 2016 and Consistence Award for implementing Kaizen in the lines related to JIPM in 2019. Recognized as Plant Senior Lead Auditor - IATF and Special Process Auditor for supplier evaluation and approved authority in South zone and North zone trained by Japanese and process are Rubber, Plastic, Injection Molding, Casting, Forging Machining, Sheet Metal Process.

Displayed paramount efforts in addressing cost issues head-on, strengthening productivity and accelerating profit at challenged operations.

Plant Head - M/s. Daechang Seat Automotive Pvt Ltd - Andhra Pradesh

(2024-09)

I am senior level plant operation head to managing and optimizing all aspects of plant operation I have a proven track records of leading to review Plant cross – functional teams improving operational efficiency, maintaining safety standards and achieving production targets. My expertise covers end to end plant operations including production planning, quality control, maintenance, supply chain coordination, manpower management, and continuous improvement initiatives. Responsible in and out of the company role.

Team strength and daily work management align with core cell. Al process to move only for the TPM way approach al function in plant goal move. Merging with two plant in one plant. EBITA improvement 13% to19% way of TPM approach on sealing plant on bottom line.

I have successfully led teams, implemented cost saving strategies and ensured compliance with all regulatory and environmental standards. My leadership ensures smooth day to day functioning of the plant while driving long term strategic goals.

• Lead end-to-end plant operations for auto component manufacturing.
• Achieved [20%] increase in production efficiency through process optimization.
• Reduced operational costs by [12%] via lean initiatives and waste reduction.
• Ensured compliance with quality standards like IATF 16949 / ISO.
• Managed a workforce of [6+] employees including engineers and supervisors.
• Improved OEE (Overall Equipment Effectiveness) and reduced downtime. ( 78% to 86%)
• Coordinated with supply chain, vendors, and Plant &customers for smooth operations.
• Implemented safety protocols, reducing workplace incidents by [30%].

Operation Head - M/s. ACE TECH Pvt Ltd.

(2021-06 - 2024-09)

Daily work Management & Team Flow strength, Daily, weekly, monthly review with core team.

Experience across functions from being an operator evolving to a plant head with top to bottom line responsibilities and strong shop floor orientation Customer interface in most parts of the career nurturing high responsiveness. Handle with Overall Plant Operations – Department CRM, Sales, Design – review, Production (Fabrication, Machining, Assembly, FAT) Quality ( In coming, Process ,Installation, Customer), SCM ( Purchase, Logistic, Outsources Stores), Electrical ( Assembly panel, Load testing, In house Routing), Installation Team review work location function handles as on day with Cutting, Welding on sub arc and robotic welding Machining in house and Hyd press as well as outsources, Fabrication, FAT setting, delivery, installation, Customer satisfaction,, process optimization, material handling to process and routing measurement, inventory control, design flow to delivery based.

Plant

Handle RM, Cutting, Machining, paint shop, assembly shop with Overall Plant Operations – In and out Plant activity, daily sales target meet with 4M meeting deep analysis on Process, product, fitment and func

Asst. Manager-Manufacturing Group Leader in Machining and Assemble Division - M/s. JTEKT India Ltd. (Formally known as SONA KOYO Steering System Limited)

(2004-12 - 2021-07)

Key Result Areas

• Front-leading the entire gamut of overall plant operations entailing O&M, Production &Planning, Supply Chain Management, Cost Management, HSE Management, Quality Management and Vendor Development
• Managing Year goals achievement activity (KMI, KPI, KAI), MFO, MPCP which is focused on cost reduction, losses reduction, productivity improvement
• Administering manufacturing process activity (Planning, Production, Engineering, Quality) Cost control System (Product, Tooling, Consumable, Repair and maintenances Power and Fuel) cost tree and losses activity
• Working as a CFT member in Manufacturing Engineering Function (Customer, Warranty, In House Quality, Engineering change Request, Engineering change note, Process change Request, Process Change Note, Drawing control window person for R&D in PPAP control in Plant level)
• Solving the problem related to productivity with CFT and problem-solving approach
• Working as a Special Process auditor for the (Casting, Forging, Machining, Sheet Metal, Rubber, Plastic, Injection Molding) trained by Japanese with Certificate audit done on TVS Rubber Madurai.
• Executing planning based on the Sales to number of shift planning, production, man power planning based on the Takt time, cycle time and standard work combination, Tools, Fixture, cost planning (Daily, Weekly, Monthly) follow up and target achievement and gap monitoring entire plant
• Feeding the cutting tool & fixture for Machining / Assembly lines as per the schedule to meet production Target
• Continual improvement through kaizen related to M/c and Operation on required Places
• Ensuring the audit related to the plant – Customer, Supplier, System audit
• Managing Process audit documents control Plant all lines
• Supervising production for the all activity in production elements with monitoring system and Floor Management Data Sheet (FMDS) – Planning of 4 M control and Improvement (Daily, Weekly, Monthly) every month achievement of (PQCDSM) Productivity PPH and PPLH, quality, cost, development, safety, Moral month on month reporting to Unit Head
• Performing Cycle time reduction by operator to SMED, Yomazumi chart, work balancing based on takt time, operator operation elimination through Automation hand movement
• Managing Layout modification related to non flow movement to single pieces flow system and avoid the un wanted man flow, Cycle time reduction, Re layout capacity utilization
• Maintaining and revising PPAP document as per Plan
• Performing revalidation of special process parameter of machine & fixture
• Managing Down time related to Process, Tool Breakage, tool reset time and Analysis and counter action
• Implementation of ECR, ECN, drawing, PCR, PCN & PPAP updating in production implementation
• Change over time reduction – TPM (video, ECRS Study, SMED, Kaizens implementation)
• Cycle time reduction – TPM (Process time – Bit Action analysis)
• Line balancing-Time study, Motion study to Improve Productivity
• Line allocation as per Schedule & Takt Time
• Re-Layout & Development of New Product on Running line.
• Implementation for Tooling cost reduction
• Providing the support for making the Fixture In House Manufacturing.
• Responsible for inventory of cutting tool & fixture
• Cost reduction based on company target
• Implementing Poka yoke (Mechanical & Electrical)
• Recognized as Active member of CFT for ISO/IATF Implementation
• POKA-YOKA introduced all new line & existing machines for error proofing
• Steered efforts in reducing machining line cycle time in 45 secs to 37 secs in Rack Bar Line
• Successfully executed Gear Line Work Balancing to bottleneck machine cycle time reduction 3 machine
• Played a key role in implementing two machining lines within 4 months and started SOP for EZGO Pinion and Rack Bar
• Installed PA & PB Tilt, Non tilt, Tilt & telescopic steering column assembly line & intermediate shaft assembly line Customer: Hyundai-i 10 & I 20
• Installed FORD Tilt & non tilt steering column assembly line Customer: FORD -FIESTA & FIGO
• Improved FORD column line PPLH from 1.3% to 3.1% through Process layout modification, introduced simple automation with the support of yamazhumi chart & VMAP 3
• Successfully improved IMS line Formation ratio up to 85% through line balancing and process layout modification by using paper doll method
• Installed H79,HHA & J92 Tilt steering column assembly line Customer: RENAULT NISSAN-DUSTER, CAPTUR & LODGY
• Successfully achieved and maintained production target in time with excellent quality
• Improved Productivity in a particular Assy line, due to simple automation technique
• Steered efforts in improving the process and product design modification to jigs & fixtures
• Played a key role in implementing Poke Yoke in assembly line section to avoid customer complaints
• Managed Layout modification for improving productivity
• Maintained rejection & down time with in targets
• Prepared One-point lesson and Visual Standard for quality alert on Processes

Diploma - Mechanical Engineering - Little flower polytechnic, Chennai (2004)

BE - Madras Institute of Technology, Chennai (2018)