Sr.Managr-Production (HPDC)

1. R. SAMINATHANR. SAMINATHAN
Mobile: 0 8 2 2 0 0 1 4 9 6 0
E-Mail: rbsaminathan@yahoo.in
Senior Manager-Production (HPDC)
PROFESSIONAL SUMMARY
23 years of experience in High Pressure Die casting of Aluminium & Zinc
Scope of expertise covers:
Production ,Process Engineering and New Product development
Last employment
From July2013-Nov 2014CRP(India)PrivateLtd,Sr.Manager-Production(Diecasting Division),Chennai
Key deliverables
• Developing production plans & schedules, arranging resources to ensure achievement of targets
as per budgeted parameters.
• Overseeing production related tasks including planning, procurement, control & troubleshooting
for achieving the planned periodic schedules.
• Coordinating with QA, Maintenance and Purchase teams and minimizing performance
bottlenecks for achieving high productivity.
• Proactively identifying areas of obstruction/breakdowns and taking steps to rectify the
equipments through application of troubleshooting techniques.
• Undertaking regular inspections to prevent accidents and adhere to safety norms.
• Executing cost saving and energy saving techniques/ measures and modifications to achieve
substantial reduction in O&M expenditures and work within the budget.
• Steering the overall planning, scheduling and management of modernization & capacity
expansion projects, ensuring completion of assignments within time and budgetary parameters.
• Planning for materials, developing vendors to obtain timely procurement of materials and
equipments to facilitate smooth production process. Monitoring projects with respect to cost,
resource deployment, time over-runs, quality compliance and manpower planning to ensure
timely execution of projects.
• Leading, mentoring & monitoring the performance of the team to ensure efficiency in process
operations & meeting of individual & group targets.
• Imparting training to the workforce for maximizing output and better working efficiency.
• Effective in problem solving, dealing with internal & external customers, effective manpower
handling.
• Proficient in communication, strong leadership skills, Able to deal with Unionized Workmen
• Manage all manufacturing driven initiatives - TPM, Six Sigma, 5"S", KAIZEN,ISO/TS - 16949, EMS
& OSHAS.

2. Additional Task
• Analysing the product geometry and optimising the product design by fine tuning the
dimensions(Radius,wall thickness,Draft,features,etc) for the smooth casting production and get
the customer approval
• Prepare tool concepts/full shot layout(single/multy cavity tooling) for the new castings after
fixing the fill time, gate velocity, plunger velocity, casting pressures and conclude the gate area
by PQ2 Analysis
• Confirm the tool concept design with casting flow analysis/simulation and fine tune the layout if
required to get the good castings and yield
• Conclude die casting process parameter (from the design & PQ2 Analysis) settings for the First of
trial and validate the tool to get good castings
• Compile the documentation of the Die casting process parameter settings/Process optimisation
for the mass production
• Develop trimming/deflashing tools
• Trouble shooting in casting defects in the running/production tools
• Support improvement activities in production, quality and tooling
• Provide training to the die casting process team
PREVIOUSE EMPLOYMENTS
Sep 2011-June2013 Chamundi Die cast (P) Ltd, Sr.Manager-Production & Process Engg,
Tumkur,Karnataka.
Key Deliverables
•Ensure Effective functioning of the production department,
•Effectively implement the good shop floor practices
•Provide training to the die casting personnel to improve their modern die casting skills
•Ensure Effective utilization of resources like Man ,Machine ,& materials
•Implement lean manufacturing practices
•Implement systematic and professional approach in trail run in new tooling
•Plan and implement effective engineering practices to achieve high OEE
•Implement appropriate actions to Reduce cost of quality
•Plan efficiently to improve inventory turn ratio
•Implement continual improvement practices
•Take necessary actions to reduce cost of production,
• Implement Waste elimination projects
• Find relevant process measures and take necessary actions for implementation and
achievement
Key Achievements:
• Implementation of systematic approach in tool design,tool tryouts with proper documentation
and PPAP run,
• Cost Reduction of consumables,(Die lube, plunger lube, plunger tip,thermocouples,etc)
• Training to die casting key personnel,

3. • Process optimisation of die casting process,
• Implementation of fully automatic die casting operation and reduce cycle times,
• Trouble shooting in die casting process and reduction of rejections
• Forming of Task force team for specific castings and achieved good improvements in good
casting yields
Feb 2006 - Sep 2011 Gplast (P) Ltd., Coimbatore
Growth Path:
Apr’08-sep’ 11 Deputy Manager - Engineering – (Die Casting)
• Setting the goal/objective for the department function and create the road map to achieve the
targets within the stipulated time frame with cost effective measures.
• Guiding the project engineers, mould designer, tool makers and the process engineers to work
together for the achievement of the objectives set for new projects.
• Bridging the gap between the design and manufacturing process by using the expertise gained
throughout the carrier path
• Monitoring the progress of the new projects and find out suitable solutions to tackle the issues
to achieve the targets
• Responsible for the realisation of the new components right from die casting tool conceptual to
the final despatch of the mass production.
• Supporting customers(Husco, Bing power,hp,TVSE) for New product developments to get the
optimised die castable parts
• Instrumental in working with key clients like Hp, Good Rich Lighting Systems, Bing Power
Germany, Argo Hytos, Rane-TRW, LTVS, Web Peripheral, etc.
• Distinction of handling product supplies across domains like Automotive, Aero space, Agriculture,
Electrical & Electronics, Domestic, Instrumentation, etc.
• An effective communicator & team leader with skills in troubleshooting, team building capability
& abilities in planning & managing resources.
Feb’06 – Apr’08 Assistant Manager - Process Engineering – (Die Casting)
Key Deliverables:
• PFMEA of die casting process & find out suitable solutions
• Reviewing the product design and suggesting modifications in the casting to get improved quality
of the casting
• Working out different die concepts & co ordinate the cast flow analysis(Flow 3D) with vendors to
get better layout.
• Die casting process planning and set the die casting process parameters to match the tool with
the machine
• Conduct trial run in new tool and process optimisation
• Identifying the need to use Laser Cusing Technology in the tooling for better thermal balance
• Planning and executing PPAP

4. • Continual improvements in the existing casting, tooling , process and yield improvement
• Develop trimming tools by out sourcing & put it in to production
Key Highlights:
• Instrumental in achieving yield improvement by optimizing the tool concept and Die casting
process,
• Lead tool life improvement from 125,000 to 300,000 shots by optimizing the tool design and
process.
• Spearheaded new product development entailing process change, machining of aluminium block
to die-casting process across ELTA Aero Space, Israel, GE Healthcare, GE Infra USA, etc.
• Developed multi cavity tooling for cost reduction.
• Reduce casting rejection in-house and customer end by process and tool optimisation
• Support maintenance department for the erection and commissioning of new die casting
machines (Frech Hot chamber 125T and cold chamber 350T machines in the year 2006).
• Provided training to die casting personnel about die casting process technology.
• Saved Rs.5,000 000.00 in a Zinc die casting (Hot chamber) component by modify the tooling and
eliminate EDM Process in the casting of 400,000 parts.
• Lead Plant power cost reduction from Rs.700,000 to Rs. 400,000.
Aug 1998 – Oct 2005 Pioneer Die Casting Industries SDN BHD, Malaysia, Head (Die Casting)
Key Highlights:
• Heading & responsible for overall performance of the department in terms of productivity,
quality and cost.
• Reduce casting rejection by process and tool optimisation
• Lead maintenance activities
• Modified the shift change over pattern from weekly to 3 weeks once, and achieved cost saving in
terms of crucible life, melting cost, reduce start up rejections.
• Imparted training to Die Casting Engineers,supervisors and Operators.
• Carry out continual improvement activities(Reduce consumption of Die lube , plunger lube,
plunger tips & other consumables)
• Generating material requirement & dispatch planning
• Manpower requirement study,capacity planning
• Ensuring optimum utilization of machine and manpower requirement study, capacity planning,
Time study, Motion study, production chart etc.
• Running 5S, quality circle & other training programs
Jun 1991 – July 1998 Eltex Rudy Ltd., Coimbatore, Production Process Engineer
(Die Casting Division)

5. Job description
• Manpower Scheduling
• Reporting of daily Production
• Rejection analysis
• Prepare Corrective And Preventive Action (CAPA) for non-conforming items / processes
/defects.
• Trouble shooting of technical problem
• Continuously focus to reduce the rework and improve the production
• Scheduling production
• Co-ordination with project owner for timely trial
• Coordination with cross functional team & follow up with internal suppliers as per schedule
• Optimum utilization of resources to meet quality & delivery targets
• Conducting training and awareness program for workers
• Ensure Health & Safety of workmen.
• Maintain all ISO documents & 5S in foundry
• Conducting daily and weekly review meetings.
• Guiding die casting operators for improving processes & quality
ACADEMIC CREDENTIALS
• MBA(Operations) in April 2015 from Ulyanovsk state university,Russia.
• Diploma in Mechanical Engineering (1st
Class,71%) in April 1991 from state board of technical
education,Tamilnadu
TRAININGS UNDERGONE
• Communication and Team Building.
• Internal Auditor Training for EOHS (ISO14001&OHSAS 18001).
• Die Casing Process control and Tool Designing from FRECH Germany.
• APQP, FMEA, PPAP.
• Supply Chain Management Concept & Personnel Development.
• Lean-Six sigma.
OTHER ENGAGEMENTS
• Member of ALUCAST,
• Watching TV ,Hearing music, Reading books, Meditation.
PERSONAL DATA
• Date of Birth: 30th
June 1973
• Address : H921, 4th
Block, Hudco Colony, Ganapathy,
Coimbatore.641006,Tamilnadu
• Languages Known: English and Tamil

6. Job description
• Manpower Scheduling
• Reporting of daily Production
• Rejection analysis
• Prepare Corrective And Preventive Action (CAPA) for non-conforming items / processes
/defects.
• Trouble shooting of technical problem
• Continuously focus to reduce the rework and improve the production
• Scheduling production
• Co-ordination with project owner for timely trial
• Coordination with cross functional team & follow up with internal suppliers as per schedule
• Optimum utilization of resources to meet quality & delivery targets
• Conducting training and awareness program for workers
• Ensure Health & Safety of workmen.
• Maintain all ISO documents & 5S in foundry
• Conducting daily and weekly review meetings.
• Guiding die casting operators for improving processes & quality
ACADEMIC CREDENTIALS
• MBA(Operations) in April 2015 from Ulyanovsk state university,Russia.
• Diploma in Mechanical Engineering (1st
Class,71%) in April 1991 from state board of technical
education,Tamilnadu
TRAININGS UNDERGONE
• Communication and Team Building.
• Internal Auditor Training for EOHS (ISO14001&OHSAS 18001).
• Die Casing Process control and Tool Designing from FRECH Germany.
• APQP, FMEA, PPAP.
• Supply Chain Management Concept & Personnel Development.
• Lean-Six sigma.
OTHER ENGAGEMENTS
• Member of ALUCAST,
• Watching TV ,Hearing music, Reading books, Meditation.
PERSONAL DATA
• Date of Birth: 30th
June 1973
• Address : H921, 4th
Block, Hudco Colony, Ganapathy,
Coimbatore.641006,Tamilnadu
• Languages Known: English and Tamil