T. Pushpavahanan

Nearly Two decades of experience in Foundry Plant Operations, Project Management, Maintenance, Production Operations, Process Management, Commercial Operations and Manpower Planning. Demonstrated abilities in supervising the complete project management cycle along with identifying new business opportunities, developing focus and providing tactical business solutions. Hands-on experience in managing operations pertaining to Melting, Molding, Pattern Making and Methoding.

Functional expertise in managing Production, Manufacturing Process & operations of Casting with key focus on bottom line profitability by ensuring optimal utilization of resources. Expertise in implementing cost saving measures to achieve substantial reduction in terms of man days, production cost, raw materials and energy consumption. Conceptualizing organization policies and planning recommendations to the management, with key focus on growth of Top line & bottom line profitability; guiding on the next course of action regarding operations by staff/ employees.

Overseeing

Techno-commercial operations viz. procuring contracts, preparing tender documents, reviewing tech. specifications, estimates, tenders and finalizing contracts. Planning materials and developing vendors for obtaining timely procurement of materials at cost effective prices. Demonstrated abilities in leading & motivating teams, organizing training programmes for enhancing the personnel skills.

General Manager – Production (Foundry) - Autotech Industries Pvt Ltd - Chennai

(2024-05)

Responsible for daily production control, target meeting with high focus on quality, taking counter measures for line defects in casting & their implementation.

• Executing cost saving techniques / measures and modifications to achieve substantial reduction in various expenditures
• Ensuring frequent productivity improvements, setup time reduction, multi machines balancing and actively responsible for meeting day-to-day production target
• Implementation of 5S, KAIZEN (Continuous Improvement) related to cost, Quality, Moral, Safety, Process improvements
• Responsible for Line balancing for new line & Existing production line for productivity improvement with coordination with process Engineering & Project Engineering Department
• Reviewing the Daily in process rejection and drive the action plan to avoid reoccurrence thro' implementation of POKAYOKE and training
• Identify and implementation of layout changes to improve productivity and resource optimization
• Deploying Lean concepts in machining – single piece flow, cell layouts
• Effectively ensuring materials management and inventory control to maintain smooth flow of materials with minimum inventory holding

General Manager – Plant Operations (Foundry) - National Fittings Ltd. - Dindigul

(2010-12 - 2024-04)

Executing responsibilities of managing overall foundry operations & commercial activities as well as taking measures for labour control & raw material control.

• Supervising foundry cost & consumption parameters like power & fuel, consumable cost, repair & maintenance cost
• Contributing new product development, detailed study of process and tooling; imparting trainings to operators and supervisors; working towards foundry manpower management
• Developing monthly production plan as per customer requirements
• To given charge calculation sheet of Induction Furnace
• Accountable for the operation of foundry in terms of productivity, quality and delivery
• Responsible for meeting the targets for the foundry on various parameters and performance
• Ensuring the production, delivery, rejection target are met with constantly monitoring on cost reduction activities in the foundry and the product quality consistently meets the customer specifications
• Ensuring compliance to quality standards [ISO/TS16949] and maintaining all related documents
• Adept at preparing SOPs, Work instructions for production operations
• Generating the daily melting schedule, ensuring proper preparations are made before pouring. i. e process control in melting
• Relining and sintering of induction furnace and operation of the induction furnace
• Managing the workmen for achieving the periodic production targets in Grey iron/S.G.iron foundry
• Planning & executing the Shop-floor operations Like Induction Melting; Charge calculation, melt composition adjustment, metal treatment, pouring
• Moulding; Maintaining the Quality and quantity of mould and moulding sand
• Ensuring sand plant activities
• Ensuring Heat treatment activities like Annealing, and Tempering
• Centrifugal casting, and all other Foundry related activities in GreyIron/ S. G. Iron foundry
• Planning BOM & raw material procurement schedules for ensuring seamless production function
• Implement / Modify and Maintain Quality management Systems in compliance with ISO 9000: and other relevant standards
• Communicating technical specifications, negotiating with Vendors, monitoring Vendor performance to ensure cost effective supply of quality material
• Negotiating & assessing the performance of the vendors based on various criteria such as prices, quality improvement rate, timely delivery, credit terms etc.
• Undertaking VA/VE (Value Analysis & Engineering) initiatives at supplier's end to reduce cost of rejection of the material supplied
• Monitoring regular production, troubleshooting & inventory control management while planning & conceptualizing strategies for accomplishment of production target within a specified time and as per predefined quality parameters
• Implementing quality management system (QMS) and ensuring adherence to the same while ensuring compliance of quality measures
• To implement modern management techniques like TQM, TPM, KAIZEN,5S,3M,etc.
• Controlling the chemical composition, casting defect analysis
• Improvement in existing tooling's
• Interfacing with clients at decision making levels to understand /resolve their technical issues and develop customized products for them to win confidence and retain their continued patronage
• Planning and effecting preventive maintenance schedules of various machineries and instruments to increase machine up time and equipment reliability
• Supervised Safety of people and equipment by ensuring safety systems are in place and rigorously monitored and controlled the sub standard conditions in the plant and ensured total safety

Foundry Manager - Sharp Castings Ltd. - Jalandhar, Punjab

(2007-11 - 2010-12)

Over all responsibilities of Production and foundry Operations. Over all control on the Department activities including production planning, Daily melting & molding planning.

• Preparation of process sheet accordingly for each SG casting iron and Rolls, Grey Cast Iron and ductile Iron
• Maintaining day wise production schedule, production report and back log report
• Prepare weekly shift wise and machine wise manpower planning report
• Coordinating Quality Control, Purchasing and marketing Person, achieve Perform to schedule goals
• Monitoring Shop Floor housekeeping
• Ensuring adherence to quality standards, implementing stringent quality control systems to enhance quality of products and reduce rejection level & rework through continuous up gradation of quality techniques
• Responsible for the % of melting loss, dross generation, heat treatment, Recovery % of extrusion process
• Responsible for Procurement of raw material and process consumables
• Responsible for maintaining all quality parameter of process to get better quality product with minimum rejection
• Heading the Foundry, Heat treatment and Forging operations
• Responsible for Productivity, Quality, Cost saving and On Time Delivery to meet the organizational metrics
• Define the Heat treatment process with respect to each Material grades
• Verification and Calibration of furnace, thermo couples & Hardness tester at periodically for ensuring its working conditions

Asst. Engineer - Melting - Auto Shell Perfect Moulder's Ltd - Coimbatore

(2004-04 - 2007-11)

Production In-charge - Adithya Ferro Cast Pvt. Ltd. - Coimbatore

(2001-11 - 2004-04)

Melting Supervisor - Bonomi Belgium Ventiel India Valves (P) Ltd. - Coimbatore

(1999-10 - 2001-10)

Melting Supervisor - Sri Padmavathi Castings Pvt. Ltd. - Coimbatore

(1997-10 - 1999-10)

Assistant Engineer - Quality - Grey Cast Pvt. Ltd.

(1996-10 - 1997-10)

Diploma - Foundry Technology - C.M. Kothari Technological Institute