VENKATACHALAM

Abdul kalam Street, Vivekananda Nagar, MaraiMalai Nagar, Chengalpattu, Chennai.

E-mail: venkatmech317@[Link] Mobile No: +91 97891 59195

BRIEF SUMMARY:
A versatile professional with 13+ years of experience in spearheading production, Manufacturing operations and
plant operations with consistent records of delivery growth and operations excellence. I am a person who has
curiosity in learning new things and update my technical skills and never procrastinate anything.

KEY SKILLS:
 Proficient in production planning and control, process inspection, manufacturing operations.
 Turn-around the business with BPR/LEAN/JIT/TQM methodologies.
 MIS preparation, Gap analysis, Problem Solving and communication.
 Process optimization, continuous improvement and efficient resource management.
 Line balancing and multi manning methods.
 8D, PFMEA, SPC, APQP.
 Cost saving Projects and Waste management.

 Delegative Leadership and People management.

Profile: Senior Executive-E3 production TVS Sundram Fasteners Ltd Since March 2025
(Powertrain Components Division) Mahindra City, Chennai. Reporting to GM-MFG
SFL manufactures and supplies powertrain components like turbine shafts, output shafts, clutch hubs, sungear
shafts, crankshaft sprockets, and slip yokes to leading automobile companies around the world (General
Motors, Stellantis, Ford, Eaton).

KEY RESPONSIBILITIES:
 Monitoring and controlling the entire Assembly & Machining Process to achieve Overall Equipment Efficiency
(OEE) with Global Targets.
 Ensuring the compliance with safety regulations and promoting a culture of safety inworkplace.
 Responsible for achieving KPI targets related to PQCDSM (Productivity, Quality, Cost, Delivery, Safety, and Morale).

 Co-ordinates and records Daily production review & Rejection review meetings in order to solve the issues
along with CFT.

 Allocation of manpower for the various lines, resolving issues arising in day to day operations.

 Must be involved in improvement activities and special projects in the organization .

 Profile: Senior Engineer-production Planning & Control From May 2023 to Feb 2025
Rane Madras Ltd, Chennai. Reported to GM-Operations
M/S Rane (Madras) Ltd is a part of the Rane Group of Companies. The main components manufactured by the
company include manual steering Gear products (SGP), Suspension & Steering Linkage Products (SSLP).The other
products include tie rod assemblies and drag link assemblies, outer ball [Link] segments like Passenger Cars,
Commercial Vehicles and Farm Tractors. Rane (Madras) Ltd received the Japanese Deming Prize and Deming Grand
Prize in 2007 & [Link] in development, Time and cost effectiveness, Flexibility and responsiveness.
ACHIEVEMENTS IN RANE:
 Successfully completed the productivity improvement projects Output increased 8 %, Cell capacity
improved 15 %, CPC reduced 15%.
 A major improvement by replacing one-way packing with returnable pallets.

 Increased productivity up 8% on boring cell by combining Piercing and roughing process(Introducing

the adequate tool in regular process which was available In market)
 Reduced peening rejection in the assembly cell from 4% to 1% by applying optimized manufacturing
processes and Why-Why Analysis.
 Implemented an air leak test method to eliminate boot puncher-related to customer complaints.
 Reduced the socket rejection by introducing self-centering fixture.
 Reduced 4 man power in Profile Tuning process (Ball rod and Ball pin cell) by using Micro cycle time
study without affecting quality, it saves cost of 8 lakhs/annum.
 Introduced a camera sensor to prevent the missing of boot support collars and boot clips.

 CPC Cost-saving projects achieved through the implementation of new-generation cutting tools and a load control
concept in the drilling process, which extended tool life.
 Executed SMED projects in drill and tap operations by integrating six variants into a single self-centering
fixture using the ECRS concept.

KEY RESPONSIBILITIES:
 Monitoring and controlling the entire Assembly & Machining Process to achieve Overall Equipment Efficiency
(OEE) with Global Targets.
 Monitoring the daily Plan vs Actual, Report preparation and DRM.
 Ensuring the compliance with safety regulations and promoting a culture of safety inworkplace.
 Responsible for achieving KPI targets related to PQCDSM (Productivity, Quality, Cost, Delivery, Safety, and Morale).

 Co-ordinates and records Daily production review & Rejection review meetings in order to solve the issues.
 Interacts with the marketing team for monthly schedule planning based on various customer requirements.
  Carries out stock verification for Finished Goods and raw materials in the production area.

 Closure of work order within two days and maintain minimum inventory WIP parts.

 Ensuring & Coordinating with the team members to achieve the JIT delivery to customers through analysis
and strategic planning based on 16 losses.

 Regularly reviews Inventory management, Waste management, 5S, 4M management through frequent
GEMBA walks.

 Directing Engineers for Kaizen implementation, Lean Manufacturing principles & Autonomous maintenance.

 Analyze and optimize existing manufacturing processes to enhance productivity, quality and efficiency.

 Active Participation and leading the QCC & QIT projects.

Profile: Senior Engineer-Quality Assurance From Jan 2022 to May 2023

Sathya Components, Avadi, Chennai.
 Reduced the part's weight from 12 kg to 11.7 kg resulting in monthly cost savings of Rs.6 Lakhs / 72 LPA.
 Implemented a timing case washing station to prevent rust and burr-related customer complaints.
 Reduced rejection rate from 12% to 5% resulting in savings of Rs.12 lakhs per month.
 Introduced material handling pallets for improved shipment efficiency
 Implemented SQC and SPC techniques in the manufacturing processes.
 Implemented ERP systems to track raw materials, finished goods, reducing unnecessary inventory.
 Internal customer development through Kaizen meetings, audits and relationship meets.
Profile: Production Engineer From July 2015 to December 2021
See Tech Indya, Chennai.
 Proficient in production planning and control, process inspection, manufacturing operations.
 Monitoring the daily Plan vs Actual, Report preparation and MRM.
 Reduced changeover time between models by implementing overlap activities, pre-planning discharge cycles.
 Increased line efficiency from 85% to 90% by eliminating non-value-added activities and driving continuous
improvements in the machine shop.
 Eliminated test piece part scrap in machining by implementing a reuse procedure, annual savings of Rs.10 lakhs.
 Applied the PDCA approach to production and quality concerns to effectively control rejection rates.
 Provides training and guidance to team members to accomplish production goals.
Profile: Engineer – Quality Control From Aug 2012 to June 2013
Butterfly Motors, Chennai.
 Ensure compliance with standards, identify issues, recommended solutions.
 Eliminate coil damage issue and introduced proper material handling methods.
 Prepare the reports on malfunctions and corrective actions.
 Work with internal teams to increase customer satisfaction.
 Profile: Graduate Apprentice & Graduate Trainee From SEP 2010 to May 2012
Rane Madras Ltd, Chennai.
 Increased Assy output From 800 to 1200 nos.
 I introduced Chamfering in the socket milling operation, so it is reduced to manual filing activity,
man power HC and Tool cost, I got Appreciation Award from the Vice President.
 Increased Ball pin cell output 750 to 1000 nos.

 Responsible for KANBAN system to be strictly followed in shop floor.

 Introduced new combination of boring bar instead of double side boring bar.

 Implemented poka-yoke in the assy line to capture the Hexagon missing problem in Ball pin.

 Implemented poka-yoke in the thread rolling machine to prevent missing pin holes in ball pin.

Profile: Technical Apprenticeship Trainee From July 2006 to May 2007

TVS Brakes India Pvt Ltd., Polambakkam.
 MIG Welding operator.
 Introduced a sensor-based poka-yoke system to prevent brake lining rejection during reverting operations.

 Got best Kaizen award for implementing coolant based machine cleaning.

EDUCATIONAL QUALIFICATION:
 M.E in Manufacturing Engineering 2013 to 2015 (8.2 CGPA) (FULL TIME)
Maha Bharathi Engineering College, Anna University, Chennai, Tamil Nadu.

 B.E in Mechanical Engineering 2007 to 2010 (70%) (FULL TIME)

Thangavelu Engineering College, Anna University, Chennai, Tamil Nadu.

 DIPLOMA in Mechanical Engineering 2004 to 2006 (82%) (FULL TIME)

Muthayammal Polytechnic College, Rasipuram, Tamil Nadu.

PERSONAL DETAILS:

Father’s name : Mr. [Link]

Date of Birth : 06.11.1987
Marital Status : Married
Languages Known : Tamil and English.
Passport : YES

DECLARATION:

I hereby declare that all the above information is true to the best of my knowledge.