Viswanathan Ganapathy Rajendran
Name V.G.Rajendran
Date of Birth 14- 06 – 1969
Present Address 23, Plot no 17, Kandan Nagar
Thiruvanai koil, Trichirappalli, Tamilnadu, India 620005
Internet:
Educational Qualifications
Languages known to read & Write: English & Tamil
Computer Literacy
Aug 1988 to Mar 1991 Worked with TVS SUZUKI Limited, Hosur, Tamilnadu, as an Assistant Foreman, in Heat Treat & Electro plating shop (including chemical & Met. lab).
Apr 1991 to Dec1999 Joined Tata Timken Limited Jamshedpur, Bihar, India (a leading Tapered roller bearing manufacturing MNC) as a Production Engineer in Heat Treat shop. For Initial one year worked with Project team, in erecting & commissioning of Heat Treatment furnaces, CNC lathes, Grinding machines, and subsequently moved to Production.
1994 to 1998 Promoted as Senior Engineer, responsible for Production, Quality, process improvements. and establishing ISO9000 quality system.
1998 to 1999 Promoted as Assistant Manager-Quality, responsible for all Quality activities of production shop floor including, Laboratory, establishing QS9000 Quality System and Vendor quality deployment.
April -Dec 99 Worked as Assistant Manager –Quality & Laboratory, with Timken India Limited (Formerly Tata Timken Limited) with added responsibility of Quality activities of Turning & Grinding Operations.
Jan 2000 to Feb 2003 Worked as Team Leader Manufacturing, with Jai Parabolic Springs Ltd, Chennai a leading automobile laminated spring manufacturer, responsible for entire manufacturing activity of the plant, including Planning, Production, Receiving Inspn., Laboratory,QA, NPD & TPM.
Feb 2003 to Feb 2005 Worked as DM – Process, with Sundram Fasteners Limited, Chennai a leading Fastener manufacturer, as Head of Surface Treatment Division (Heat Treatment, Zinc Plating, Phosphating, Torque modifier coating) with additional responsibilities of Management Representative for Environmental Management System, & TPM Co-ordinator to get TPM Consistency Award ( 2nd Level after TPM Award)
Feb to 2006 Worked as Asst. General Manager- Manufacturing, with Sterling Tools Ltd Faridabad a high tensile fastener manufacturer as Asst General Manager Manufacturing. ( A competitor of Sundram Fasteners Ltd. Quit from here as objections received from Sundram Fasteners )
Feb 2006 onwards: Worked with Sanmar Foundries Ltd, a constituent of Sanmar Group as Head of operations(Asst General Manager) supplying castings to Valve segment (Gate, Globe, Check, Plug, Ball, Butterfly, safety relief, Control, valves), Rail road segment, and Earth moving Equipment segment. . Joined without Foundry experience, to implement operational excellence practices. Established Value streams, Lean management,quality management systems, Environmental Management systems, 5S, TPM Concepts, Safety systems,Theory of Constraints, 6 Sigma deployment etc.
Jan 2010 to Dec 2012: Asst Vice President -Heading the Marketing of Sand Foundry, Investment Foundry and Machining center.
Jan 2013 onwards Business Head- Investment foundry division.
Current Responsibilities
Achievements - Current Assignment (Steel Sector)- Passed SSLC from Coimbatore with 74% in 1984
- Passed Diploma in Mechanical Eng. from Coimbatore with 85 % in 1988
- Passed Graduation in Metallurgy through Associate membership examinations of The Indian Institute of Metals Calcutta, in 1998
- Passed Diploma in Management in Jun 2002
- Presently doing MBA through IGNOU.
- Lead assessor for ISO14001 systems ( Passed exams with 80%)
- A member in the Indian Institute of Metals, and SAE Technical Forum.
- A certified internal auditor for ISO 9000, and QS 9000 Quality systems.
- Qualified Energy Manager, Awaiting Certification by Bureau of Energy Eficiency India
- Qualified on Lean Manufacturing and TPM Implementation
- Goldratt Consultancy Trained implementor of Theory of Constraints
Languages known to read & Write: English & Tamil
Computer Literacy
- Proficient in Office2000 ( Word, Excel, Powerpoint, Access, Publisher, Front Page),
- Excellent knowledge in web designing
Aug 1988 to Mar 1991 Worked with TVS SUZUKI Limited, Hosur, Tamilnadu, as an Assistant Foreman, in Heat Treat & Electro plating shop (including chemical & Met. lab).
Apr 1991 to Dec1999 Joined Tata Timken Limited Jamshedpur, Bihar, India (a leading Tapered roller bearing manufacturing MNC) as a Production Engineer in Heat Treat shop. For Initial one year worked with Project team, in erecting & commissioning of Heat Treatment furnaces, CNC lathes, Grinding machines, and subsequently moved to Production.
1994 to 1998 Promoted as Senior Engineer, responsible for Production, Quality, process improvements. and establishing ISO9000 quality system.
1998 to 1999 Promoted as Assistant Manager-Quality, responsible for all Quality activities of production shop floor including, Laboratory, establishing QS9000 Quality System and Vendor quality deployment.
April -Dec 99 Worked as Assistant Manager –Quality & Laboratory, with Timken India Limited (Formerly Tata Timken Limited) with added responsibility of Quality activities of Turning & Grinding Operations.
Jan 2000 to Feb 2003 Worked as Team Leader Manufacturing, with Jai Parabolic Springs Ltd, Chennai a leading automobile laminated spring manufacturer, responsible for entire manufacturing activity of the plant, including Planning, Production, Receiving Inspn., Laboratory,QA, NPD & TPM.
Feb 2003 to Feb 2005 Worked as DM – Process, with Sundram Fasteners Limited, Chennai a leading Fastener manufacturer, as Head of Surface Treatment Division (Heat Treatment, Zinc Plating, Phosphating, Torque modifier coating) with additional responsibilities of Management Representative for Environmental Management System, & TPM Co-ordinator to get TPM Consistency Award ( 2nd Level after TPM Award)
Feb to 2006 Worked as Asst. General Manager- Manufacturing, with Sterling Tools Ltd Faridabad a high tensile fastener manufacturer as Asst General Manager Manufacturing. ( A competitor of Sundram Fasteners Ltd. Quit from here as objections received from Sundram Fasteners )
Feb 2006 onwards: Worked with Sanmar Foundries Ltd, a constituent of Sanmar Group as Head of operations(Asst General Manager) supplying castings to Valve segment (Gate, Globe, Check, Plug, Ball, Butterfly, safety relief, Control, valves), Rail road segment, and Earth moving Equipment segment. . Joined without Foundry experience, to implement operational excellence practices. Established Value streams, Lean management,quality management systems, Environmental Management systems, 5S, TPM Concepts, Safety systems,Theory of Constraints, 6 Sigma deployment etc.
Jan 2010 to Dec 2012: Asst Vice President -Heading the Marketing of Sand Foundry, Investment Foundry and Machining center.
Jan 2013 onwards Business Head- Investment foundry division.
Current Responsibilities
- Responsible for Business development, Pricing, Customer services, and all day today activities 100 tons per month Steel Investment Foundry Unit,.
- Achieve Business Objectives of Sales, OTD, EBIDTA, Market sustinence, New Product development, 6 Sigma deployment, Succession development, and plan for Expansion of capacity.
- Introduced the surcharge mechanism, to take care of Non metallics, Power, & Fuel price fluctuation.
- Introduced Currency correction factor, in the pricing structure to have consistant contribution irrespective of Foreign exchange.
- Successfully revised the Pricing structure with surcharge mechanism and currency correction factor for CAT, GE, SPX, and Major Valve customers to improve the contribution.
- Implemented Lean Management & Value streams and Improved production from 450 tons/month to 900 tons/month during my first year in Foundry 2006-07, with an EBDITA improvement from 4% to 14% & Capacity utilisation >95%
- Implemented & certified for ISO14000 Environmental management system.
- Successfully transferred the business & knowledge on parts for Caterpillar casting manufacturing, which is 50% of installed capacity. Currently supplying at 700 tons per month and would reach 1200 tons/month by Q2 of 2011-12
- Expanded the capacity with State of the Art facility to manufacture 100 tons of castings per day (2008-09) Visited IMF Italy, for aquiring hands on training, and dry run trials of Fast loop automated molding line (May 2007)
- Created 6 Sigma blackbelt resources, and deployed 6 Sigma culture in the organisation. Caterpillar trained “6 Sigma deployment champion”.
- Successfully implemented the Theory of Constraints concept, through Goldratt Consultancy
- Brought-in the culture of 5S & TPM and achieved 740 points in CII scale of 5S external audit, in sand foundry.
- Visited Keokuk Steel Foundry & Richmond Steel Foundry at USA, to transfer knowledge (2008)
- Installed the state of the art, Sand reclamation plant (by thermal method), to conserve natural resource and cost.
- Pepset mold making in IMF autoloop, Continuous mixers upto 60ton/hr capacity, Thermal sand reclamation, mechanical sand reclamation, Shell molding, Isocure core shooters, Shell core shooters, Pepset core mixers, Alcohol based and water based Spray & flow mold coat systems, auto closer and Pattern management system(PMS).
- Induction melting furnace of 150 kgs to 8 ton capacity Dual track.
- Exposure to Low alloy steel, Carbon steel and High alloy steels of various grades, Pressure equipment directive, AD Merkblatt, Various class society approvals, WPS, qualification etc.
- Gas & arc cutting, Various stainless steel Heat treatment processes, shotblasting and Fettling, Pickling etc.,
- Various Sand parameters testing, qualifying the sand quarry, Resin parameters, and mold coat qualifying process, Sleeve qualifying process. Etc
- UTM, Sub zero Impact, Hot tensile, IGC, Dry MPI, Wet Mag, DPI, RT,UT, Hydro leak test etc.
- Area of EXPOSURE during the entire 23 years of Industrial Experience ( Mainly Automotive Sector )
PRODUCTION:
- Foundry Operations: Induction steel melting furnaces, Core shooter, Shot blasting, Pepset and Shell molding, fettling, etc.
- Forge & Press shop operations: cold forging, thread rolling, Shearing, Pressing, punching, forming, deep drawing, Rolling, cutting, bush fitting etc.
- Gear shop operation: including, milling, broachng, hobbing, grinding etc.
- Machine shop & Assembly operations : Turning, Grinding, Honing, Broaching, Reaming, boring, milling, Rivetting, Assembly, Bull dozing, Packing, Shrink wrapping etc.
- Various types of Heat Treatment operations: Carburising, Hardening, Press quenching, Hot rolling, taper rolling, Tempering, Carbo Nitriding, Normalising, annealing, Stress relieving, Hydrogen De-embrittlement, etc
- Various Corrosion resistance operations, Zinc plating, Copper plating, Zinc Phosphating, Auto phoretic Coating, Dacromet and GeoMet coatings, Painting, R.O & DM water generation, Waste water treatment, etc.
- Special Surface treatments: Shot peening, Stress Shot peening
QUALITY SYSTEM:
- Development of Quality systems as per ISO 9000, QS9000, ISO 14000, TS 16949, Telco’s CQ standards, Toyota standards etc.
- Performing FMEA, SQC, Gauge R & R, MSA (Linearity, Bias, Stability, Uncertainity), PPAP, APQP, LQSM, and capability studies.
- Radiography, Dye penetrant test, Magnetic Particle test, Flourescent magnetic crack detecton, sand test, Gel test, Cube test for sleeves, Dimensional measurements, Surface finish measurements ( Ra & Rz), Vickers Hardness, Brinnel hardness, Rockwell hardness, Inclusion rating, grain size rating, Spectro analysis, Micro and macro structure analysis, Fatigue failure analysis, Decarb analysis, Jominy hardenability test, Salt spray tests, bend tests, Coating thickness, coating adhesion tests, grinding burn injury tests, UTM tests, case depth measurements ( Ms test, Vickers traverse and carbon cut ring methods), sieve analysis Pyrometry, Thermal profile, Temperature uniformity, Travelling temperature, Millipore Dirt count, Water content in oil, pH, Bacteria slide test on water soluble emulsions, Evaluation of rust preventive oils, etc.
- Dial Test calibrators, Calibration of Surface tables, Measuring instruments like Vernier, Micrometer, Measuring scale, Gauges and fixtures, Pressure gauges, Flow meters, Thermocouple and Controller calibrations, Force monitors, Thickness testers, Pitch gauges, etc.
- Selection of vendor, Vendor Registration & evaluation, Development of Organisational supply standards, Vendor Quality assessment, Quality audit, vendor performance rating, Training & development of vendors.
- Project evaluation, Justification & Viability assessment, Capex, cashflow, NPV & Payback, Utilities & Service requirement planning, Supplier co-ordination, Installation, Erection & Commissioning, Preliminary capability studies, Process establishment, standardisation through Process flow, work instructions and procedures.
- Other Managerial analysis, Contribution analysis, Payback analysis, Networth analysis, Economic Batch qty analysis, Career planning, Succession planning, Negotiation techniques, etc
- Held position of Kobetsu Kaizen Pillar Chairmen at Jai parabolic Springs Ltd. Held position of Jishu Hozen Pillar Chairmen, at Sundram Fasteners Ltd.
- Hands on experience on implementation of JH & KK pillar activities. Thorough exposure to Kaizen, Pillar theme generation, 5S, 16 loss identification & analysis, OEE & OPE analysis, QI story techniques, Skill matrix, POKAYOKE, QA Matrix, 4M Analysis, PM Anlaysis, SMED implementation, Visual management & control in operations, etc.,
- Developed Training assessment process, to evaluate the effectiveness of Trainer and the trainee.
- Developed conducted Technical training and conceptual training on following
- Technical Training: a) Metallurgy for Non-metallurgists, b) Lean manufacturing, c) Visual management, d) 5S Implementation e) Industrial Safety, f) Road safety, g) Safety on Material Handling, h) Safety on Chemical handling, i) How to implement SMED?, j) QA Matrix and alternative to FMEA, k) Surface treatments for Fasteners, l) Fastener application and selection, m) Shot peening process control and application, n) Statistical Process control, o) TPM Implementation, p) Kaizen-Pokayoke conceptsNon-Technical Training: a) Negotiation skill, b) MS office software, c) Presentation skill, d) Communication skill, e) Time management etc,
- Presented a paper on “ Friction modifiers in Fastener coating” at National Metallurgist Day held at Indian Institute of Technology, Chennai in Nov 2004
- Presented a paper on “ Nitrogenless atmosphere in case Hardening” at National Metallurgist Day held at Indian Institute of Technology in Nov 2004
- Presented a Paper on” Fatigue Behaviour of 50 Cr V 4 springs when subjected to Stress shotpeening” in the ASTM International Surface treatment conference helt at Chennai during Jan2004.
- Presented another paper on “ Case Hardening – A shop floor managers Perspective” at international conference ASTRA held at Hydrabad in Nov 2003”
- Won the national Second position “BEST KAIZEN AWARD”, in the First Kaizen conference conducted by CII and JIPM at Delhi during Sep 2002
- Held JH pillar chairmen position and Won the “TPM Consistency award” from the JIPM (2005)
- Did a project on Accelerated Continuous Improvement (developed by Mckinsey) realizing 40 % Savings per annum on Cost, Quality, and Service. (1998)
- Visited Ford Technical Centre UK, to present about plant facilities and capabilities, and bagged the order, to supply Transit suspension for Europe.(2002)
- Visited Germany for procuring SCHATZ a fastener character analysis equipment. Did the best negotiation and saved Euro 9500 (2005)
- Developed all documents, established the system as per ISO 9000, QS9000, TS16949 and ISO14000 standards. Faced number of certification and surveillance audits.
- Worked with Tata research development center on Energy savings project, and realized 24% gain in capacity and 18% savings in Energy. Worked with PCRA, on Energy conservation of Oil fired furnaces and achieved 14% savings in oil consumption. (2002)
- Using theory of constraints,did process optimization in automated Zinc plating line to increase the capacity by 40% without capital investment at Sundram Fasteners Ltd Similar process optimization done in Zinc phosphating line also and achieved 45% capacity increase (2004)
- Did process optimization in Sterling tools limited in the Heat Treatment line and increased OEE to 95% in continuous hardening furnace.(2005)
Languages known to speak: English, Tamil, & Hindi
Languages known to read & Write: English & Tamil
My Strengths
Strong believer in Systems & Collabrative team work. Mingling with layman & Strong heads with open mind for learning and improvement with team involvement
Achieve performance by setting direction, targets and quick decision making.
Good analytical and communication skills.
Good Trainer. Aquiring indepth knowledge about the speciality of the product and process.
My Weakness
Believer in judicial decision on risk. No Risk-No gain; Failure means lesson learnt.
Patience and perseverence in reaching the targets.
Not interfearing in the areas not responsible.
My Beliefs
Strong believer of God, ethics, and “We are what We think”
My Values
Transparancy, Loyalty, Puncuality, accountability
Countries Visited
United Kingdom, United States of America, Germany, Austria, Italy, Malaysia, Singapore, Srilanka
References: can be obtained from: http://in.linkedin.com/in/vgrajendran
Customers & Product Handled:
VALVE SEGMENT: Emerson Process Management ( Fisher ), Tyco, Xomox, Crane, Pacific, SPX, Copes Vulcan, Cooper cameron, Gator, Orton, Truflorona, Zwick, Poyam, Westad, Lazaro, BS&B, Flowserve, Itag etc
RAILWAY SEGMENT: Bombardier, Alstom, Siemens, GE, EMD, Cardwell, Knorr Bremse, Faively
CONSTRUCTION & MINING: CAT, KOMATSU, Swing stetter, BEML,
ACHIEVEMENTS PHOTOGRAPHS
Won the Kaizen Award National level at the First Kaizen conference Delhi 2002. Presented by Mr Kapoor of Sona Koyo, Mr Yamaguchi is also present.
Signing the contract for the Supply of Schatz a fastener testing Equipment with the German Supplier (June 2005) at Germany.
Got appreciation from Mr Timken Jr for successful implementation of Accelerated Continuous Improvement Project (1998) Mr Vinod Dasari The then Director Manufacturing of Timken India ( Currently CEO of Ashok Leyland) is also present.
During the plant tour onsite presentation of successful implementation of Accelerated continuous improvement Project with Mr. W.R Timken The Chairmen Timken Company, and John T Elssasser, Vice President of EAWA Business
posted by VGRAJENDRAN at 4:09 AM
