1. PROFILE
NAME : G. SHANMUGAM
PROFESSION : PRODUCTION ENGG. AND MFG. SYSTEMS ENGG.
CONSULTANT.
CONTACT DETAILS : Mobile – 98412 30574
Email – gsm720@hotmail.com
QUALIFICATIONS : Graduate in Mechanical Engineering.
PGDBA in Loyola Institute of Business Administration, Chennai.
EXPERIENCE : 1. Having 32 Years of work experience in Production Engineering
and Manufacturing Functions in M/S BRAKES INDIALTD, TVS
Group Company, holding Senior Position.
2. Offering Consulting Services for the last 10 years in Production
Engineering, Methods Improvement, Projects,New
Products/Process Development, Cost Reduction, Cycle Time Reduction,
Single Piece Flow and PPM reduction for various Companies situated in
Chennai, Delhi, Coimbatore and Bangalore.
COUNTRIES VISITED:
1. Japan in 1980 for Training in CNC Turning Centres.
2. West Germany in 1984 for Training in CNC Machining Centres.
3. Japan in 1994 for Process / Manufacturing Systems Study on
Caliper Brakes Manufacture.
DETAILS OF EXPERIENCE:
 6 Years as Jig & Tool Designer.
 18 Years in Process Planning, Process Proving, Cost Estimation
(for New Products), Methods Improvement (Cost /Cycle Time
Reduction) for BRAKE Components Machined on GPM, SPMS &
CNC Turning Centres / Machining Centres and Capital Equipment
Selection, Proving & Installation.
 3 Years in Press Shop manufacturing sheet metal components for
brake parts.
 2 Years as Production In-charge, managed 105 Work Force in
Manufacturing Unit for Brake Master Cylinders, Testing &
Assemblies.
 3 Years in Manufacturing Systems Engg. in New Products
Introduction, Mfg. Cells Design & Capacity Planning /
Equipment’s Selection.

2. SPECIAL TRAINING:
Undergone special training for 3 weeks with Prof. Sudha, (renowned
Japanese TQM Consultant) on Gap Analysis & Exactness.
AS CONSULTANT :
Since 10 years, offering Consulting Services for the following clients.
Sl
No
Client Name Responsibility
1 Rane (Madras) Ltd., Chennai PED Advisor
2 ELFORGE Ltd., Chennai Mfg. Engg. Consultant
3 OMAX Autos Ltd., Haryana
4 Plants – Dharuveda, Speedomax,
Automax & Sprocket Division.
Prime Supplier to Hero Honda Ltd. for
8 years
BPRE Consultant
4 AUDCO India Ltd. Chennai - 3 Plants Mfg. Engg. Consultant
5 SAKTHI AUTO CAM, Bangalore
(Prime Supplier to MICO)
Machining Consultant
6 MAKINO Auto Industries, Noida
(2 Wheeler Clutch Manufacturing)
BPRE Consultant
7 SHAKHI Foundry, Coimbatore Machining Consultant
8 Liners India Ltd., Vijayawada Machining Consultant
9 Roop Auto Ltd., Sohna BPRE Consultant
10 Sandhar Auto Components, IMT, Gurgaon BPRE Consultant
11 Suja Shoei Pvt. Ltd., Chennai
(Rubber Parts Manufacturer for Brake
Parts)
Technical Advisor
12 Dedicated Suppliers to Brakes India Ltd.,
Chennai
Mfg. Engg. Consultant
SPL. WORK AREAS:
1. Hands-on experience in all CNC Machining and Turning Centres in
Programming, Cycle Time Reduction, Trouble Shooting, Tooling
Improvement, Process Proving and Optimizing Capacity
Utilization.
2. Improving / Introducing New Process / Methods.
3. Mfg. Systems Engg. Design & Implementation (Single Piece
Flow/Lean Mfg. Systems)
4. Cost Reduction and Improving Bottom line.
5. Overall Productivity Improvements.
6. Improving OEE (Overall Equipment Efficiency).
7. PPM Reduction by Effective use of SPC Techniques/Process
Improvements.
8. Effective use of Manpower & Improve value added per Employee.