Senior Manger Operation in Automobile Manufacturing

1. S SATHISH BABU
1A 8th Street, Annai Vellakanni Nagar Extn, Mobile: + 9176657065
Mugalivakkam E-Mail:sabu_s_18@yahoo.co.in
Chennai -125 Date of Birth: 18th May, 1983
Passport No: J8094047
Talented and decisive professional offering more than 17.8 years managing entire Business operations in
core production process with Training and shop floor management system implementation through strategic
leadership in Automobile Industry.
At present working with NIPPON STEEL CHEMICAL AND MATERIAL INDIA PRIVATE LIMITED as Senior
Manager – Manufacturing. Leading the manufacturing operations and Product Engineering functions
reporting to Plant Director. Manufacture of METAL SUBSTRATE(Catalytic Converter) for 2W, 3W, with high
design and technology performance to the EMISSION-REGULATION.
Core Competencies
 Manufacturing & Operations: Well versed with new mass production & continuous process
technologies, assembly processes, Vacuum furnace technology, Metal Substrate technology for
EMISSION&DURABILITY application.
 Project Management: Monitoring/ tracking project operations with respect to budgeted cost, demand
forecasts, time over-runs to ensure timely execution of projects. Budgeting and scheduling along with
resource allocation. Engineering, design and materials co-ordination internally with global team &
externally with SUPPLIER&OEM.Technical co-ordination with client for the NEW-Programs.
 Lean Manufacturing & Best Practices: SMED, 3”M”, 5”S”, Kaizen, Poka- Yoke, Kanban, TPM, Time
study- Motion Study, JIT, Work measurement, Productivity improvement drives, Quality Circle, Single
Pc. Flow production system, Resource utilization, OEE Improvement, Model m/c concept, Problem
solving through CFT, TAKT Time calculation, Manning norms standardization through
DFMEA&PFMEA methodology.
 Operations/Business Excellence: Departmental objectives & Individual KRAs, Target setting, Bench
marking, Innovation & Continuous improvement.
 Quality Management Systems: Lead Auditor in ISO 9001:2015.
Career Progression
Tenure Company & Designation
Since Mar’13
Apr’09-Feb’13
Oct’06-March’09
March’05-Sep’06
Oct’01-Feb’05
Nippon Steel Chemical and Material India Pvt. Ltd- Chennai Senior Manager –
Manufacturing Management(Supplier for 2W&3W)
Renault Nissan Automotive India Private Limited as Incharge – Senior Engineer Production
Weld shop(BIW)
Hyundai Motor India Private Limited as Incharge-Junior Engineer production Weld
shop(BIW)
ThyssenKrupp JBM as Incharge- Production Engineer weld shop(BIW)
(Supplier for FORD INDIA PVT LTD CHENNAI)
General Auto Engg. as Incharge –Production Engineer weld line
(Supplier for LUCAS-TVS CHENNAI)

2. Company : Nippon Steel Chemical and Material India Pvt. Ltd. Chennai
(Green Field Project)
Designation : Manufacturing -Senior Manager.
Tenure : Since Mar’13 to Till date
Key Responsibilities:
 As a GREEN Field Project initiate all plant activities like plant layout optimization, machinery
procurement Installations, process qualifications & Improvements, Zero defect analysis, QMS
implementation, the synchronized production technology.
 As a Factory Manager direct & co-ordinate the manufacturing Team related Factory
Act&Regulation,license submission of documents to authorities, and key person to support SHE team.
General Task Management:
 Handling entire plant operations including Production, SCM, Maintenance, Quality and Process
Engineering..
 Responsible for developing and implementing business plan, capex, budgets, costs, controls and
product deliveries for the production unit.
 Interacting with (Domestic/Overseas) customer at Mid/Senior level(R&D,Engineering&Quality).
 From the Engineering Trial to SOP process managing the program documentation.
 Coordinating with all new program activities and follow up with program Masters (OEM) and
scheduling (with Design&Engineering).
 Responsible for Project management and preparing master schedule plan and follow up.
 Preparing and consolidate the department reports for the top management review.
 Ensure the operations to achieve cycle time and concerns related to operator fatigue and workability.
related to SQDCE (Safety, Quality, Delivery, Cost, &Environment )
 Establish open & transparent communication within the team, improve team work
 capacity utilization of manufacturing by the bottlenecking process reduction in time cycle
 Increase in batch size and implementation of all process improvement projects as per schedule
 Communicate KPIs from the strategic annual plan so that each employee is aware.
 Continue to focus on the efficiency and meeting the production standards/ output requirements
 Prepare Corrective Action Reports for Customers and internal concerns as may be required.
 Responsible to design effective material flow to maintain the min inventory levels & to improve the
Working capital.
 Collaborate with support functions like Sales, purchase, Logistic; HR & GA to achieve the smooth
work flow.
 Champion a program for the implementation and sustainment of a continuous improvement culture
 Responsible for the optimum utilization of floor space available.
 Take part in the development of NSCM, as tool expert and design.
 Responsible for self-learning and coaching the team members in implementation of NSCM culture in
the plant.
 Reviews with tooling engineering, Customer & Supplier personnel where required.
 Ability to manage a variety of cross-functional team members.

3. Achievements in Shopfloor
1. Vertical Growth Award for the year -2014.
2. Highest overseas sales plan achievement for the year -2015.
3. Achieved Zero customer complaint for the year-2016
4. Highest overseas sales plan achievement for the year -2017
5. New Model development award for the Year -2018
6. Successfully completed the BSIV application for the 2W&3W.
7. Reduced lost time accident
8. Successfully set up” Global Training school” for the employees.
9. Cost down reduction and achieved high productivity in Vacuum Furnace.
Company : Renault Nissan Automotive India Pvt Ltd. Chennai.
(Green field project)
Designation : Senior Engineer - Weld Shop & (Global Master Trainer-Weld shop)
Tenure : Apr’09 – Feb’13
Responsibilities in shop floor:
 Responsible for achieving shift production with SQCT.
 In charge of Body side assembly line having 50 Team members& Four Team leader producing
BS/shift.
 Overseeing production as per process/process improvements for Zero defects.
 Studying and identifying the bottlenecks & hindrance for productivity improvements, finding
solution to implementing and stream lining the production process.
 Preparing Job allocation & Line balancing using 13 Guide Line Principle.
 Well knowledge about multi model mix based on Line Balancing Technique like Course Analysis,
Element Analysis, Occasional &Non-Cyclic Analysis.
 Establishing the Standard Operation sheet by applying Four Principle of Motion Economy for various
types of SOS (work instruction)
 To facilitate Kaizen for implementation of new innovation activities.
 Providing the direction to team members in order to enable efficient production begin.
 Benchmark data’s from other Nissan plant to improve the production process.
 Sharing the best practice to improve for efficient to run the production to resolve the operational
issues.
 Train & guide SSV/SV/TL on N-TWI / Job observation based on needs.
 Online and Offline Training to be given with help of 3 Step Teaching Method or PEDPEP Method.
 Skill Training for the Sub-ordinates to achieve (I L U) level as per Matrix Management Method.
 Responsible includes providing directions to resolve quality issues and ensure maintenance to the
environmental standards (QMS&EMS).
Achievements in Shop floor
 Increased the OEE Capacity from 75% to 80%.
 Ergonomics study, layout study, and welding gun installation in lines.
 Back tip improvement done in BODY SIDE to avoid spot deformation.
 Process improvement in sealer application Micra & Sunny.
 DPHU reduction in Body side assembly (LH&RH) from 17% to 9%.
Company : Hyundai Motor India ltd. Chennai
Designation : Junior Engineer
Tenure : Oct’06 – Mar’09
Responsibilities in Shopfloor:

4.  Responsible for Establishing New Projects & achieving the production target.
 Robotics spot weld programming in HHI robotics.
 Responsible for Customer Quality Audit/ Field Complaint problem Analysis.
 Implementation of ISO 14001 in the department & maintaining documents/system effectively
 BIW problem solving in line.
 New development in jigs & fixture for bottle neck areas.
 Improvement activities - BIW Production Line , like Gap Analysis.
 Manpower planning & controlling in jig departments responsible for stabilizing new projects &
achieving the production target.
 Attending production problems managing production operations with a view to ensure
accomplishment of production targets within the time & cost parameters.
 Monitoring production, keeping control over activities & analyzing processes for line balancing
thereby ensuring smooth operations.
 Co-ordination of Side line erection for new projects.
Improvements - for Internal Customer Defects
 Responsible for Customer Quality Audit - Paint / Assembly / PDI problem Analysis
 Quality Management – Improving the BIW quality through innovative improvements
 Co-ordination for Implementation of QS-9000 and ISO – 14001 qualities.
 Successfully Reduced M.P.C rejection trend with in short period.
 Initiated Quality related training programs for all Technicians & CL`s
 Ensuring quality problems for gap problems.
Major Achievements - Hyundai
 Productivity improvements in side line by means of cycle time reduction from 74 sec’s to 64 sec’s.
 Operation efficiency improved from 85% to 90%.
 Establishment of 56 uph.
 Cost saving for sealer pump (multi usage in 3 stations).
 Process improvement in sealer application Getz & Verna roof sealer application’s.
 Process improvement in roof rail storage.
Educational Qualifications
Route
 Bachelor of Science in engineering technology in 2013 from “Birla Institute of
Technology & Science - Pilani” - Rajasthan.
 Diploma in Mechanical Engineering from 1998-2001 in K.S.R. Institute of Technology,
Thiruchengode, Namakkal Distt.
Overseas Training
 Process training program in Nippon steel and Sumikin material plant – Japan (Nagoya & Takaoka)
 Management Training program in PT.Nippon steel -Indonesia(Jakarta)
 New product development and Machine modification Training program in Nippon steel-China(Hangzhou)
 Shop Floor Management Training program in Nissan Motor Sunderland plant - United kingdom, for 3 months
From May-2009 to July-2009.
 Certified as Global Master trainer (Weldshop) from Nissan Motor Sunderland plant - United kingdom.
 N-TWI Trainer(Train the Trainer to Develop the standard operation Sheet)
Awards
 Global Master Trainer in weld shop for Renault&Nissan Plant.
 N-TWI Global Trainer(Train the Trainer to Develop the standard operation Sheet)
 YK04 Trainer(How to do the Standardization)
 Certified Global Trainer for Nippon steel Plants
Certified Course
 Completed Lead Auditor in Quality Management System(ISO 9001:2015) IN TUV NORD-Certified by
CQI and IRCA(certificate no:3524 2762 01)