Plant head

BOOPATHY MARIMUTHU – MBA, B.Tech (LSSGB)

Creative, Intelligent, Ambitious Leader - Targeting to pursue a rewarding career with senior level challenging assignments in MANUFACTURING / OPERATIONS / PROJECTS / MAINTENANCE of Forging, Foundry and FMCG Industries

Senior Professional with over 29 years of rich experience and 5+ years in Heading Operations ensuring YOY Growth Performance to achieve PBT %. Manage and Control Cost Centers with Quality and OTD. Pilot, Implement, Establish, Monitor and Control Business Initiatives in Line with Management Strategy under Integrated Management System in dynamic and demanding environment

Phone: +91-978******* E mail: adljjb@r.postjobfree.com

Professional Experience:

Since Jul’2019 : HF Power Technologies, Chennai - Head Operations (BD, Admin, Mfg, Purchase, Finance, QA) Jan’2018 – Jul’2019 : Suguna Foods Ltd, Coimbatore - Functional Head (Hatchery Division) - AGM

Jan’2017 – Dec’2017 : Hinduja Foundries Ltd, Chennai - Head Maintenance - Divisional Manager

May’2010 – Dec’2016 : TVS Sundram Fasteners Ltd, Chennai - Head Maintenance - Sr. Manager, Manager (Dy. Plant Head)

Sep’2004 – Apr’2010 : MM Forgings Ltd, Chennai (Trichy Plant) - Head Maintenance - Dy. Manager, Asst. Manager

Sep’2003 – Aug’2004 : Magna Electro castings Ltd, Coimbatore - Head Maintenance - Asst. Manager

Sep’2000 – Aug’2003 : MM Forgings Ltd, Chennai (Trichy Plant) - Team Leader Maintenance

May’1991 – Aug’2000 : Pillar Induction India, Chennai - Senior Engineer & Engineer (Commissioning & Servicing)

May’1988 – Apr’1991 : Rajaselva Chemicals Pvt Ltd, Trichy - Shift Engineer

Key Result Areas: PQCDSM

Lead and achieve the PBT % as per BP target

Manufacturing Management of Quality, Quantity, OTD and Optimum cost

On-time completion of Capacity expansion and NPD with less lead time to meet Market demand based Business growth

Focus on new projects investment ROI

Assets and Resources optimum utilization

Upkeep 4M conditions to achieve best quality performance and implement QIP to reduce overall rejections

Implement effective Cost saving and Energy saving projects to achieve and maintain the manufacturing cost within norms

Facilitate for 100 % Delivery adherence

Significant Accomplishments:

Suguna Foods Pvt Ltd:

10% Improvement of Own Hatcheries utilization from 75% to 85%

10% Capacity expansion from 80 Cr to90 Cr Egg Setting through Green and Brown field Projects

0.4% Reduction in rejections from 1 % to 0.6% by reducing the return chicks.

10% Manufacturing (Hatching) Cost reduction from INR 1.55 to1.45 / Egg & R&M cost reduction from INR 0.30 to 0.25 / Egg

7% uptime improvement from 90% to 97% through systematic and periodical review of RCA and YY analysis

30% improvement of SOP adherence to 80% from 50%

Implemented 100% Digital Instrumentation in Process and IoT technology for hatchery remote monitoring

100% training of staffs achieved Pan India

Hinduja Foundries Ltd (Ashok Leyland):

5% uptime improvement from 80% to 85% and 10% increase in Productivity from 4500 MT to 5000 MT

3% Reduction in Repair & Maintenance cost by indigenization of spares and internal skill development.

100% Timely review through RCA and Counter measure implementation for repeated BD occurrences

High employee morale by Zero Major Accidents and 100% Statutory compliance

TVS Sundram Fasteners Ltd – Green Filed Project for Wind Energy Fasteners Plant - Hot Dip Galvanizing facility in 1 year time

Lead the new business vertical revenue under Integrated Management Control with 22% contribution and 15% PBT

Improved sales revenue from 15 Cr to 90 Cr progressively in 4 years of start(15- 40- 65-90 Crs)

Achieved Project investment cost within budget to meet the ROI in 3 Years.

Manufacturing Management of 500 MT Per Month to meet Sale of INR 8 Cr consistently

Ramped up Monthly Production capacity from 300 MT to 500 MT within 2 years of start

Installed additional Forging line for M27 to M36 Bolts manufacturing for capacity enhancement

10% productivity improvement from 4.5 to 5 MT / Day of Heat treatment furnace by optimizing the cycle time.

Reduced overall rejections from 1.5% to 1.0%

5% Cost saving through RM consumption, R & M cost, Machine modification, Tool life improvement and spares indigenization.

On time NPD of Tower, Nacelle and Blade fasteners for windmill, Solar and Infrastructure applications

Established Nut forging up to M36 in-house to reduce outsourcing cost

Established End to End Execution of Concept to Production then to Delivery for Make in India initiative New Product Line

Homologation champion - Global customers GE, Siemens Gamesa, Suzlon, Regen Power, Win wind, Vestas, Inox, L&T, BHEL, Reliance, Taco, Gammon India and Sun Edison

MM Forgings Ltd:

Established 6 Brown field Forging Lines set up for capacity expansion

Monthly Forge shop BD reduced from 75# to 25 #

PM team formed for improved PM adherence from 40% to 80% which reduced minor stoppages

Oil furnace consumption reduced from 120 Ltrs to 90 Ltrs/Mt

Magna Electro castings Ltd:

Sand plant PLC program modified and established the process automation

Additional mold handling line established for productivity improvement and reduce metal holding time

Improved accuracy of Bentacoal and Bentonite addition through VFD automation

Transformer rewinding carried out and re-installed in 7 days (Primary to Secondary short - lightening surge)

Pillar Induction India Pvt Ltd:

Efficiently attended more than 50 Service calls in quickest time during 4 Years tenure.

Successful commissioning of Induction Furnace, Induction Heating and Hardening equipment for Foundry and Forging Industry

More than 35 installations in 5 Years period ( 50 Kw to 3000 KW with 100 Kgs to 6000 Kgs melting furnace)

International Project - 3 lines (500 Kw with 2 X 1000 Kg melting furnace) - Greater Cairo Foundries, Cairo – Egypt

Key Impact Areas

Integrated Management System (ISOs, OHSAS, QMS, TPM, TQM and Lean Six Sigma)

Business Development & Customer relationship

Risk Management, SWOT Analysis

Cost Saving through Business Process Improvement

Lean Management

Total Productive Maintenance & Kaizen

Problem Solving & Customer Complaint Management Internal & External Customer Satisfaction

Team Building & Leadership

Employee Engagement & Training

Maintenance Management & Project Management

MTBF & MTTR improvement

Career Timeline

Soft Skills

Communicator

Collaborator

Intuitive

Innovator

Leader

Motivator

Analytical

Team Builder

1998-1999

2000-2010

2003-2004

2010-2016

2017-2017

2018-2019

Pillar India

MM Forgings Ltd

Magna Electro castings

TVS Sundram

Hinduja Foundries

Suguna Foods

Chennai

Trichy

Coimbatore.

Fasteners Ltd.

Limited, Chennai.

Ltd. Coimbatore

Chennai.

Executive Profile

Manufacturing process establishment under compliance with proper scheduling including outsourced process to ensure quality product is delivered on time.

Solve problems with Team Work, Management support and HR development by Training.

QMS/QA/QC and Operational Process Improvement by Liaison with Suppliers, Customers and System Certification Bodies for both Domestic and International Products.

Customer Complaints and CAPA, Root Cause Analysis, Supplier Evaluation.

Deployment of ISO - TS, TPM,TQM, Tools and Technique like 7QC tools, FMEA, APQP, PPAP, Kaizen, Poka-Yoke for continual improvement and Management Tools for Production and Process Management.

Review on Planning, Productivity, Plan V/s Actual Delivery & Production performance, 5S, Sales, OEE, Inventory Status, and Analysis with team on Losses summary.

Review of productivity, consumable and man power efficiency for variable cost control.

Present Monthly MIS report of Plant performance to Management.

Improve Productivity by eliminating NVA, Utilization of Operators and machine Time.

Team Player with strong Leadership, Communication, Profit driven and Interpersonal skills.

Liaison for statutory approvals and Certifications – TNPCB, TNEB,ISO,TPG,OHSAS,CE

Attend Management review Meetings and conduct Plant level review meetings

Kaizen and CIP for cost reduction

Ensure safety to achieve Zero Accident

Training need identification and Skill development

Establishing successful vendor network for out sourcing activities

Machinery assets handled:

Induction Furnace, Sand Plant (Conveyors, Bucket Elevators, Mixer, Knock out, Vibratory feeders) Molding Machines, Mold handling Lines, Pouring lines, Sand Pumping, Core Shooters and Drying Ovens, Heat Treatment Furnaces (SQF, Continuous type, Batch type) Electrical, Oil & Gas fired, Shot blasting m/c, Cranes and Hoists, Induction Heaters, Forging Press & Hammers, Trimming Press, Shearing Machines, Power Band saws, CNC Lathes, Milling machines, EDM, MPI machine and Coining press, Automatic Incubation machines, Crumbling M/c, Hammer Mill m/c

HT Yard, Transformers, VCBs, MV panel, ACB, PCC, MCC, MLDB, SSB, DB, LDB & PDB,DG sets, Compressors, Dryer, Chiller, HVAC, Boilers, and Cooling tower, RO Plant, STP, ETP, LPG, Diesel Storage yard, Fire Hydrant and Sprinkler Systems, Fire alarm and Smoke detector systems.

Education

MBA-Technology Management:

Anna University, Chennai- Jan 2013

CGPA: 6.4 / 10

B.Tech, EEE; SASTRA University, Tanjore - Dec 2007

CGPA: 7.5 / 10.0

DEEE, DOTE, Chennai May 1988

% Marks: 83 /100

Certifications

LSS GB – MSME Chennai

Kaizen Expert – MM Forgings

Expert TPM Facilitator and TPM Practitioner – SFL, MMF & Magna

Expert TQM Facilitator and TQM Practitioner – SFL & HFL

Trainings

Situational Leader ship, Managerial effectiveness, Interpersonal skills improvement, Operations and Manufacturing Excellence, Project Management, Supply chain management. Finance for Non-Finance Managers, Capability building for trainers, Employee wellness and Mentoring workshop, FMEA, APQP, PPAP, SPC, MSA, Problem Solving Technique, 8D, 7QCTools, Kaizen and 5S

Soft Skills

MS Office, SAP, Mini Tab

Personal Details

Date of Birth : 13th June 1970

Language Known : English, Hindi, Tamil

Passport #. : L4672349; Validity: 17-Dec-2023

Current Address : D-1, Step Stone Arthitha Apartments, Pulikoradu, Tambaram West, Chennai - 600045

Permanent Address : 1/37, Main road, Nakkasalem, Perambalur DT. Pin 621118

Contact this candidate