R.

SUNDAR
E-mail ID:sundarramanr18@yahoo.com
Mobile: +919894365971

Career Objective:

Operation Professional with extensive experience in the field of World-Class Manufacturing

system. Possess excellent coaching and communication skill necessary to develop strong work
team and drive results through employee empowerment. Hoping to secure a challenging position
in an organization where my abilities will be maximized for achieving organizational objectives.

Career Profile:

 A Mechanical Engineer with nearly 12 Years of extensive functional experience in managing

manufacturing operations with encompassing Lean Manufacturing System, TPM and TPS.
 Currently Working in Brite Brothers Limited as Deputy Manager.
 Worked in K.L.N College of Engineering as Assistant Professor/Lean Manufacturing system
Consultant.
 Worked in TAFE as Sr.Engineer.
 Worked in TVS – SUNDARAM BRAKE LININGS LIMITED as an Engineer.
 Smart worker and an effective communicator with excellent relationship management &
interpersonal skills.
 Involved in Production and capacity planning activities based on monthly customer demand.

Qualification Highlights
 Ph.D in Lean Manufacturing System – Anna University, Chennai.
 M.E – CAD/CAM from Mepco Schlenk Engineering College (Anna University), Secured
7.8 CGPA.
 B.E - Mechanical from Sethu Institute of Technology (Anna University), in 2006.
Secured 70 %
 XII Standard from Indira Gandhi Matric Hr Sec School, Madurai, Tamil Nadu in
2002.Secured 79%.
 X Standard from Indira Gandhi Matric Hr Sec School, Madurai, Tamil Nadu in 2000.
Secured 69%.

Organizational Experience

 Deputy Manager - Manufacturing Engineering in Brite Brothers Limited. Sep.12 to

Still Date.
 Assistant Professor/Lean Manufacturing system Consultant – K.L.N College of
Engineering, from Jun.12 to Sep.19.
  Sr.Engineer – Production Engineering in TAFE from Aug’11 to Jun’12 –Manufacturer
of Tractor and farming equipment.
 Manufacturing System Engineer in TVS – Sundaram Brake Linings Limited
from July’07–June ’09.An ISO/TS 16949:2002 Company Manufacturing Brake
linings, Clutch facings, Disc pad & Railway Block for light motor & heavy motor
segment.
 Service Engineer in SHM(Singh Hindustan Marine Pvt Limited – Mumbai from
Aug’06-‘07

Work Profile and Area’s Handled in Brite Brothers Limited:

- Coordinator of the team in driving the TPM Program & Culture

- Responsible for implementing lean manufacturing system
- Implemented TPM pillar in overall plant activity
- Responsible for developing and monitor the TPM KPIs
- Coordinating with team for improving MTBF and MTTR
- Responsible for improving JH and KK pillar.
- OEE monitoring & increase OEE by reducing losses like Set up , Tool change, break downs
etc.,
- Conducting morning meeting at team levels on yesterday’s pan Vs Actual, customer
concern.
- Today’s plan, manning, has to be discussed with the shift in charge and facilitating to do the
day today activity.
- Driving QC, CFT projects based on customer complaint.
- Responsible for implementation of LCA(Low cost Automation) and Poka Yoke.
- Responsible for Plant Utilization and Production target achievement.
- Responsible for Capacity Utilization & Validation.
- 5S Coordinator
- Optimized Man and Machine utilization by Man – Machine Analysis
- Plant Expansion.

Significant Accomplishments

- Improved OEE from 77 % to 85%

- Improved MTBF from 2 to 7 days and Reduced MTTR from 3.5 hr’s to 1.2 hr’s.
- Reduced Breakdown Percentage from 3 % to 0.8 %.
- Introduced Special Purpose Machine (SPM) for Balance ring Assembly Line.
- Introduced customized heater set-up fixture in Hot-Plate Welding Machine
- Implemented Factory Visual Management System.
Work Profile and Area’s Handled in K.L.N College of Engineering:

- Responsible for handling engineering subject

- Lean Manufacturing System Consultant
- 5S Coordinator
- Placement Training Co-coordinator

Significant Accomplishments

- Published a Journal on “A Review of Lean manufacturing Implementation

Techniques” and the same journal is cited by 95 researchers throughout the
world.
- Published a Journal on “ Analyzing the Performance of Lean Manufacturing
Implementation with Chronological Execution of Lean Elements using Spread Sheet
features: A Case Study
- Implemented Lean manufacturing system elements such as Cellular
manufacturing system, Flow manufacturing, U- line system.
- Implemented Break-through machine for reducing Bottleneck process cycle time.
- Model a Design for Product Process Tracking (Applicable for Fixed demand with fixed
cycle time).
- Increase the production capacity from 10,000 No’s to 40,000no’s/shift.
- Pull cycle time design throughout all the process.
Work Profile and Area’s Handled in TAFE:

- Control and Planning day-to-day strategies in Cell 5 (consists of 21 stages

- To ensure production and delivery of Tractors as per daily and Weekly plan as per multi
model mix
- Driving QC, CFT projects based on customer complaint & PDI complaints
- Organizing CFT meeting and finalizing the process design.
- Visual system & 5s implementation to organize the work place and for proper identification
of components in the assembly shop
- Productivity improvement and eliminating bottle neck areas through video study analysis
- Responsible for implementation of LCA(Low cost Automation)
- Responsible for implementation of Poka Yoke
- Responsible for coordinating QA regarding customer complaints and closing NC.
- Responsible for implementing FM (Flow Manufacturing)
- Time studies, Work studies and Motion Studies for improved productivity improvements.
- Layout modification, cell design, Line balancing.
- Improve the Productivity by Continual improvements (Kaizen), Creating the Standard
work, SOP, operator Work Balance, Creating work sequence and Continuous flow

Significant Accomplishments

 Implemented Moving Parts Kitting System.

 Implemented Stationary Parts Kitting System.
  Implemented Battery manipulator for battery handling
 Conversion of Main line activity into off line activity by implementing seat sub
assembles fixture and conveyor.
 Implemented Low cost automation for oil draining system.

Work Profile and Area’s Handled in TVS – Sundaram Brake Linngs Ltd :

- Responsible for Production planning & coordination.

- Responsible for Marketing Sales Plan Adherence
- Responsible for Plant Utilization and Production target achievement.
- Responsible for Capacity Utilization & Validation.
- Accountable for shop floor Productivity and O.E.E.
- Responsible for educating and training the employees in OJT, 5S, TPM, TQM, Lean,
TPS, SMED, Kaizen
- Worked in the TPS team. TPM pillar in KK pillar.
- Optimized Man and Machine utilization by Man – Machine Analysis
- Responsible for Production planning (Gentani – kanban creation), Man power allocation,
Material Planning, Dispatch schedule planning.
- Design and modifications the Factory Layout and Cell layout for Manufacturing and store
units
- Time studies, Work studies and Motion Studies for improved productivity improvements.
- Layout modification, cell design, Line balancing.
- Improve the Productivity by Continual improvements (Kaizen), Creating the Standard
work, SOP, Operator Work Balance, Creating work sequence and Continuous flow.
- Designing the Jigs and Fixtures for CV Linings.
- Designing creative and innovative solutions to fix and prevent problems by involving the
CFT teams.
- Responsible person for setup time reduction activities by applying SMED concepts.
- Designing and implementing error proofing devices in all over the process.
- Eliminating the wastes in operation, 3M study, Safety guards and Poka-yoke’s designing
and providing Facilities thereby Increasing Output and Decreasing Operator’s Fatigue.
- Perform VSM & Lean action workouts (Kaizens) with local team and guide the local
employee to facilitate small lean action plans on their own.
- Capacity calculation, Process planning, Machine/Equipment Planning for the Process.
Creating better Material flow by implements new material handling systems.
- Preparing operation wise Production control plans, Work instructions and setting
instructions.
- Productivity improvements. Kanban system implementations in Stores, Shop floor and
supplier end.
- Lean implementation throughout the plant.
- Responsible for Cost estimation, Purchasing capital goods, Raising Sanctions for the
projects to the top Management.

Significant Accomplishments
  Enhanced the line capacity through Single Piece Flow by Cell Layout Design.
 Design on Auto indexing mechanism.
 Implemented Poka Yoke to Weighing system.
 Reduce Mould C/O time from 90 Min to 15 Min by implementing SMED.
 Reduce Space and oil consumption by Redesign of Power Pack Tank.
 Implemented Material handler Man Concept.
 Implemented Kanban System, Heijunka and FIFO.
 Manpower reduction by introducing Low Cost Automated Printing.
Training and Certificate

 Presented International conference Paper on “Review on Lean manufacturing

Implementation Techniques.
 Presented National conference Paper on Design and Fabrication of Semi
Automated Packing Machine
 Attended certified LEAN training course contacted by ABK AOTS DOSAKI on
behalf of TVS Sundaram Brake Linings Limited.
 Attended certified SMED training course contacted by ABK AOTS DOSAKI on
behalf of TVS Sundaram Brake Linings Limited.
 Attended training course on TPS.

IT Skill Set
 Operating System : Windows Packages, Open Office Packages
 Development Tools: AutoCAD, Solid Works.

Other Details
Father Name : R.Raman
Date of Birth : 18th JUNE 1984
Location : Madurai.
Languages Known : English, Tamil.
Hobbies : Reading Books, Playing Cricket.
Address : No: 41, PKP Housing,
Valarnagar (OPP to Reliance Market),
Madurai.
Declaration:
Hereby I declare that all of the above information furnished is true to the best of my knowledge
and honesty.

Place:
Date: R.Sundar