Kathirvel

Results-driven Manufacturing & Operations professional with 35+ years of experience across CNC machining, machine shop operations, fabrication, and quality systems. Proven track record of delivering over ₹56 lakhs in annual process cost savings through CNC optimization, fixture engineering, and lean manufacturing initiatives at Titan Company Ltd.

Held General

Manager roles across three organizations, leading cross-functional teams, implementing TPM/TQM/5S cultures, and consistently meeting production targets. Certified in IATF 16949 Automotive Quality Core Tools and ISO 9001/14001/45001 internal auditing. Passionate about building high-performance shop floor teams through structured problem-solving and continuous improvement.

General Manager - BESTOMECH INDUSTRIES - Coimbatore

(2023-12 - 2025-02)

• Directed end-to-end CNC operations, conventional machining, fabrication welding, painting, assembly, packing and dispatch for a precision auto components manufacturer.
• Developed and implemented operational strategies and policies that kept production processes aligned with targets and forecasts.
• Drove OEE improvement initiatives through structured employee training, resulting in measurable gains in on-time delivery and customer satisfaction.
• Led Total Productive Maintenance (TPM) rollout to improve machine uptime, performance reliability, and asset lifespan.
• Maintained strict regulatory and quality standard compliance across all shop floor operations.

General Manager – Operations - GISHNU GEARS PVT LTD - Coimbatore

(2021-01 - 2023-11)

• Oversaw in-house and outsourced manufacturing covering laser cutting, punching, bending, painting, and powder coating.
• Implemented skill matrix system to evaluate operator competency and drive targeted training in inventory management, costing, TQM, TPM, 5S, Kaizen, and safety management.
• Conducted periodic supplier and external provider audits to enforce quality standards throughout the supply chain.
• Launched employee engagement programs with rewards and recognition for top performers, improving team morale and retention.

General Manager – Operations - BARANI HYDRAULICS INDIA PVT LTD - Coimbatore

(2018-01 - 2021-01)

• Enhanced operational efficiency contributing significantly to the company's expansion; managed TIG/MIG welding for yoke fabrications, laser cutting, bending, deburring, and painting.
• Led Cross-Functional Teams (CFT) to consistently achieve plan-vs-actual production targets with right quality and cost efficiency.
• Implemented stage-by-stage process monitoring to eliminate customer complaints and maintain zero-defect delivery targets.
• Executed internal audits for ISO 9001, ISO 14001, ISO 45001:2015 and IATF 16949 quality management systems.
• Performed SWOT analysis to drive continuous improvement and on-time delivery commitments.

Machine Shop Manager - AQUA FLOW - Coimbatore

(2016-01 - 2018-01)

• Managed all aspects of machine shop operations including production scheduling, quality control, and safety compliance.
• Established and managed process flow and production planning for CNC Turning, VMC (Vertical Machining Centre), VTL (Vertical Turret Lathe), and HMC (Horizontal Machining Centre) operations.
• Developed and managed process flow for Injection Moulding operations, ensuring cycle time optimisation and dimensional conformance.
• Applied Lean manufacturing principles to optimize production flow and eliminate waste.
• Identified and implemented cost-saving initiatives; monitored inventory levels and supply chain operations.

Engineer (Machine Shop) - TITAN COMPANY LTD - Hosur

(1989-01 - 2016-01)

27-year tenure at India's premier precision manufacturing company. Delivered ₹56+ lakhs in documented annual process cost savings through CNC innovation, tooling engineering, and productivity improvement initiatives.

• Tripled tool productivity by redesigning links trimming and shaving tools from single-row to triple-row profile, improving output by 200%. (Process cost savings ₹20 lakhs per annum)
• Reduced CNC Wire EDM Machine setting time, saving 60 hours per month through setup optimization. (Process cost savings ₹5 lakhs per annum)
• Developed interchangeable fixture for CNC Milling Machine, eliminating idle time during setting process. (Process cost savings ₹6 lakhs per annum)
• Engineered compound die sets with multiple stages, achieving higher-level productivity improvement in press operations. (Process cost savings ₹15 lakhs per annum)
• Delivered raw material savings through the 'Knock the Tail Out' waste reduction project. (Savings ₹5 lakhs per annum)
• Redesigned cutting oil return line in CNC Milling Machine to eliminate oil spillage and mechanical failures. (Cost savings ₹2 lakhs per annum)
• Improved end mill manufacturing and resharpening process, extending tool life and reducing replacement costs. (Savings ₹3 lakhs per annum)
• Developed aerospace component manufacturing processes at Wire EDM (WEDM) for Hindustan Aeronautics Limited (HAL) — demonstrating precision machining capability for defence-grade standards.
• Designed and developed fixtures for CNC Wire EDM Machines to improve dimensional accuracy and productivity.
• Achieved quality improvement in outer trimming pilot manufacturing through process re-engineering.
• Trained employees in machine operation, quality concepts, safety procedures, and lean tools throughout the tenure.
• Established and maintained quality control procedures to ensure consistent conformance to specifications and standards.

MBA - Production Management

Diploma - Mechanical Engineering