R.

SURIYANARAYANAN,

SENIOR CONSULTANT

(PROCESS EXCELLENCE & QUALITY - VENDOR

AUDITING/IMPROVEMENT)

Contact : +91-9600030750

Email : [email protected]

SUMMARY:

• 1.5 years’ experience of working in technically advanced, cost-efficient and state of the art Quality systems in
FRANCE

• Skilled in ensuring strict compliance with regulatory guidelines, Vendor assessment and development in
Planning, Creating, controlling of IMS in TPM, Lean, ISO 9001-2015, ISO 14001-2015 and ISO / TS16949-2002
Documentation / Methodology.
• Pioneering experience in process excellence using Lean concepts , created Single piece flow in Line Balancing to
Takt, Increased Per man productivity, Reduced Inventory, Increased OEE by managing and continuously
improving effectiveness of processes.
• Proven leadership in enhancing productivity & operational effectiveness by optimizing resource utilization,
improving quality and achieving cost reduction/waste elimination
• Strong exposure in leading large teams of 1200 + members and achieving best performance across multiple
business lines

• An enterprising leader with strong strategic planning, communication, interpersonal, analytical & negotiation
skills.
OBJECTIVE :

• To Study the Current state of the Industry in terms of Process, Flow from Raw material stage to Dispatch stage,
Do Gap Analysis, Create Future state by Eliminating : Non – value addition activities, Inventory, waiting, Excess
manpower.
• Increasing the Overall line efficiency and training the Manpower to adopt to this culture with less energy
consumption and Moving forward the organization to reach to the world class standards and achieve Business
goals with First time Right Quality in Supplier level, In- House operation and achieving Customer Delight.
• To assess Vendors for their Capacity, Capability to achieve Customer Required Quality, Cost and on time delivery
with Full quantity, Do gap Analysis, take actions and develop the Vendor team to next level and review them on
defined Frequency to have control, Maintain and sustain the improvement standards at all times.
PROFICIENT IN PROCESS EXCELLENCE :

• 5’s Implementation, Creating Visual Factory,

• Elimination of 3M( Muda, Mura, Muri ),
• 7 Waste ( Transportation, Inventory, Excess motion, Waiting time, Over processing, ) ,

• 3C( Constant container, Constant Quantity, Constant Location) concepts.

• Process Mapping using a swimlane diagram - Current state, Gap Analysis, Future State - Cycle time analysis -
balancing to Takt time with Bottle neck cycle time Identification - Changing from Batch production to SPF (
Single piece flow ), LLF ( Low lot Flow – 20 – 30 nos/batch )- Inventory Control- Increasing per Man productivity
– Implementation of Kaizen – Poko – yoke’s ( Prevention, Detection )
• Increasing : OEE ( Overall Equipment Effectiveness) – By Increasing Availability : Set-up time Reduction using
SMED concepts – Eliminating Down time – study MTTR – MTBF – creating – Preventive maintenance – Predictive
maintenance – Condition Based Maintenance – By Increasing Performance : Tool life monitoring – spare parts
management - Jigs/Fixtures, Hand tools , Accessories management – Cycle time balancing – By Increasing
Quality : Daily Rejection / Rework Analysis using Pareto/ Cause – Effect tools – Maintaining process capability
within the control limits - Change Management in Man, Machine, Method, Material – Leader ship skills -
Problem Solving Skills - Decision Making Skills -Team Building Skills - Time Management - Stress Management -
Self Awareness & Self-Management, Supervisory Skills - Communication Skills - Personality Development -
Operational Excellence - Customer Handling & Customer Satisfaction.

PROFICIENT IN VENDOR AUDITING/IMPROVEMENT :

• By Vendor Auditing : Assess the current level of capability – capacity - Quality PPM level - Customer satisfaction in
terms of : Quality – Cost - On-time Delivery in Full quantity - Customer Rating – Quality - Environment - Safety
Certification ( Aspect / Impact study ) and their validity.

• Training the Vendor to follow : 5 Core tools – APQP – 5 phases – PPAP – 18 documents with 5 levels of submission
– MSA – Gauges – Attribute – Kappa study – Variable – GRR – Linearity – Bias – Stability – Calibration plan vs actual
– FMEA – DFMEA , PFMEA – Severity – Occurrences – Detection – RPN – Risk Analysis , Mitigation – SPC ( Statistical
Process Control ) – Calculating Sigma to 6 Sigma – Plotting Control limits – study process variation, mean and Range
– calculate Cp ( Process Capability) – Cpk – ( Process Capability Index )- Fixing review Frequency to maintain the
consistency in Quality.

• Training to Review the Production Plan Vs Actual – meeting Customer Demand – Contingency plan for 4 M losses
due to Natural Calamities – Analysing, take actions to Eliminate 16 major Losses – Produce in controlled condition
in Energy, Manpower and Inventory consumption.

INDUSTRIES HANDLED :

• Construction • Automotive / Non-Automotive Manufacturing • Traders • IT and IT Enabled Services • Packaging

Industries • Warehouses • Training Institutes

CAPABILITY SUMMARY:

• Overall 27 years of professional experience in Manufacturing , Quality Auditing/ Improvement , Process

Excellence, Vendor Development, New Product / Project Development – Capex, Revenue Budgeting, Preparation of
TNI Calender for Employees based on Product/ Process requirement, Skill enhancement in Manufacturing,
Education, Construction, Traders, Packaging , Warehouse , & Service Industry.

EXAMPLES OF ACHIEVEMENTS IN PROCESS EXCELLENCE / VENDOR AUDITING, IMPROVEMENT :

• Played a key role in Decreasing rejection rate ↘: 10% to 1000ppm through Quality Circles, SPC,6 sigma
and process optimization
• Increasing through put up by reducing lead time and optimizing material movement across the site

• Improving OEE ↗: 55% to 75% by implementing 5S, loss elimination, improved up time in at bottleneck /critical
machines, equipment by doing PM’s and setting-up time reduction ( SMED Concepts)
• Improving the quality of the raw materials ↗ by >90%by monitoring critical impurity parameters trend analysis
• Reducing WIP inventory ↘: 7days up to 2 days, raw material inventory: from 10 days to: 4 days and FG
inventory: 5 days to 1.5 days by fixing economic buffer using statistics and demand driven planning & material
movement
• Eliminating breakdowns by transfering To CBM, TBM, increased the frequency of PM activities and reducing
MTTR & Increased MTBF.

• Improved flexibility in production cells using Bib Flex and SMED Concepts.
• Reduced set- up time ↘: 5 hours to 1 hour in ASV body machining cell through SMED and BIB flex concepts

• Reduced set- up time ↘: 7.5 hours to 3 hours in Forging machines and achieved :Rs.20 lacs /Annum - Cost
saving through SMED concepts

• Optimized Raw material cutting length , there by reduced End piece scrap ,achieved a cost saving of : Rs.10 Lacs
/Annum – Cost saving.

• Created 1 Lean cell Reduced Manpower from : 11 persons to : 7 persons/ shift ( 4X3 = 12X10kX12 = Rs.14.40
lacs) Final inspection persons – 4 persons to 2 persons/shift ( 2X3 = 6X10k X 12 = Rs.7.20 Lacs) Total Savings is =
Rs.14.40 lacs + Rs.7.20 lacs = Rs.21.60 lacs /Annum – cost saving is achieved.

• Reducing cost of each project and achieved cost saving of Rs. 25Lakhs through negotiation in new machines
and by implementing new Kaizen, Lean concepts in new projects.

• Decreasing rejection cost ↘: Rs. 5 Lakh/month to Rs.10,000/month by implementing prevention and

detection Poke-Yoke and by using 7QC Tools & QC Story Analysis

• Improving quality parameters (Cp & Cpk) in rejection high machines and rejection cost by selecting correct
operation, method, tool material & cutting parameters and monitoring tool life

• Amplifying productivity ↗: 400nos/day to 800nos/day by using Micro-motion Study and Process Innovation

• Improving Tool life in Aluminum Alloy Castings ↗: 20,000 nos. to 80,000 nos. by introducing new Grade
tools (Coated Carbides to PCD) and altering to corrected cutting data

• Creating VSM for Current and Future state, Kanban, Visual standard factory, there by reduced Product
waiting time ↘ :3 hrs to 1 hour (Changed from Push to Pull system)

• Proving ECM Machine for R0.5 in Internal Hole, Match Precision Grinding Machine – clearance up to 1.5
microns & taper 1.0 micron

• Coordinating with the depart Heads and leads to develop the Training Module for the gaps in the required
skill set of employees to achieve business goals of the Organization

• Excellent in Small Business Unit set ups & to make it end to end operational excellence in short span of time

• Training Strategy for aligning the learning for achieving the Business Goals of the Organization

• Marketing Strategy for a successful Business delivery.

EDUCATION DETAILS :

• Bachelor of Technology (Automobile Technology) from Anna University with 65% marks in 2004

• Bachelor of Business Administration from Madras University with 55% marks in 2000

• Diploma in Mechanical Engineering from Coimbatore Institute of technology, Coimbatore with 77% marks in
1991
CERTIFICATIONS :

• Certified ISO: 9001-2015, ISO :14001-2015 Lead Auditor

• Certified Six-Sigma Black Belt Champion by Anna University with “A” Grade.

• Certified ISO / TS16949 – 2002 - Internal Auditor, VDA 6.3 – Internal Auditor, MSA course

• Certified Auto CADD – 2018 professional

• Certified Primavera – P6 professional

LANGUAGE PROFICIENCY :

• English (Full professional proficiency)

• French ( Average professional proficiency )

• Telugu (Average professional proficiency)

• Tamil (Native or bilingual proficiency)

• German ( Basic proficiency)

OVERSEAS, INDIA ASSIGNMENTS / TRAINING :

• Intensive course on powerful operational management, leadership, and team motivation for excel in their goals
– attended for 6 weeks in FRANCE.

• Attended training on : TPM, Lean and New Product Development tools at Mikuni Corporation, JAPAN.

• Auditing & Coached: Supplier Quality Engineering Audits & done Process Improvements in Suppliers end at:
TAIWAN & THAILAND. Done many internal audits as per ISO/TS 16949 - 2002

• Completed : New projects in Steering systems for M/s. IFA, Germany with supplier assessment and development
in. M/s. Sumi mother son, with Sub – Suppliers M/s. New Tech, Chennai, M/s. Vel Tech, Madurai.

• Hydraulics Training at Yuken India Ltd., Bangalore

• Completed: Safety Training by CII at Madurai &Poke-Yoke and Kaizen at MPC, Chennai

• CNC Programmes on Machining, Milling and Turning Centers at Excell CNC Centre, Chennai

• Training on SPC, SQC, DOE, Standard Cell Documentation for Common Rail Application at Chennai

• In- House Trainings on Improvement of Managerial Skills, VSM, Line Balancing to TAKT , Lean
management, Basic maintenance training and Identifying & carrying Out PM1, PM2, PM3 Activities
to Eliminate Breakdowns.
RECENT PROCESS EXCELLENCE / AUDITING , IMPROVEMENTS :
M/S. SSA Business Principal Consultant: Feb. 2023- Present
Solutions Pvt. Ltd., Operational excellence projects using lean, 6 Sigma
Mumbai methodology, Studying the current state mapping, check
opportunities for improvement in inventory, manpower,
machinery control and implementing it & achieving huge
profits.

Inclusive of training in new skill development based on their

current skill level

M/S. Tata Projects, Auditor: Jan. 2018- Jan. 2023

Hyderabad Vendor assessment and Audit the existing vendors
Preparation and issuance of compliance report which
includes review of P&L statement, quality documents,
customer complaints & redressal, legal and safety
adherence , etc.)
 Process Excellence:
1. TPM Tracker- IoT enabled IT system creation
2. Data analysis and management of the actions
taken in addressing the failures. Developed
Customer Complaints & Redressal (CCR)-System
with the MIS.
3. Developing the Inventory and Material
Management System (Work in Progress)
4. Setting the KPI and monitoring the project team
M/S. Tata Projects, Auditor: Nov. 2022- Jan. 2023
Hyderabad Audit the vendors on their processes
Financial and team management
Legal, safety and environment activities
M/S. Emmbros Process Improvement Consultant: Feb. 2022- Oct. 2022
Automotive Pvt. Ltd., Heading Operational excellence Projects using lean
Baddi, Himachal manufacturing and 6 sigma methodology
Pradesh Reduced downtime by TPM activities
Reduced setting time by SMED concepts
Conducted quality system audits, and achieved huge cost
savings
M/S. ACMA, Pune Senior Consultant: Sep. 2021- Jan. 2022
Administering Operational Excellence Projects
Process mapping and Manpower optimization
Establishing process improvement activities

M/S. Ramsays Quality Head: Oct. 2020- Aug. 2021

Corporation – Vendor, Production, and Quality management
Chennai Client Delivery management
Plan for Instruments and training
Customer Complaints Redressal
M/S. Srinivasa Operations Manager: June 2020- Oct. 2020
Engineering works, Inventory and Resources management
Maraimalai nagar, Vendor management
Chennai Logistics and delivery chain management

M/S. IFA, Germany Interim SQA Program Manager: Oct. 2019- Mar. 2020
DRS Approval
Vendor assessment
Prototyping, Pre- launch Product build, and execution of
customer requirement

SOME OF THE KEY CLIENTS OF MY PROCESS EXCELLENCE / VENDOR AUDITING , IMPROVEMENTS ARE :

• M/S. THIRUPATHI TUBES AND FITTINGS PVT.LTD., SECUNDERABAD,

• M/S. DESIGNETIC UPVC SOLUTIONS PVT.LTD., CHENNAI.
• M/S. ECO RCC PRECAST PVT. LTD., VIZAGAPATNAM
• M/S. DREAM DESIGN CONSTRUCTIONS PVT. LTD., GHAZIABAD,UP.
• M/S. S.J.CONSTRUCTION PVT. LTD., MORVI, GUJARAT.
• M/S. FLUIDO HYDRAULIC TRADING & ENGINEERING SERVICES, KACHERIPPADI, KERALA.
• M/S. DURGEE AUTO SPARES PVT. LTD., KANIHA, ORISSA.
• M/S. V & s ENTERPRISES PVT. LTD., PUNE, MAHARASHTRA.
• M/S. SUNITHA SALES CORPORATION PVT. LTD., BUDHWARPETH, PUNE, MAHARASHTRA.
• M/S. URBAN BLAZE LEATHER PVT. LTD., KANPUR, UP.
• M/S. LIBERTY INTERNATIONAL PVT. LTD., BANGALORE, B.O: 14402, BETHANY AVENUE, CHINO ACA, USA.
• M/S. MALHARI MARTAND RMC PVT. LTD., JUCHANDRA, MAHARASHTRA.
• M/S. SAAD ENTERPRISES PVT. LTD., NEW DELHI.
• M/S. EPP COMPOSITES PVT. LTD., KALWAD ROAD, METUDA, GUJARAT.
• M/S. RUHI ENTERPRISES PVT. LTD., PALGAHR DISTRICT, MAHARASHTRA.
• M/S. N.M.STONES PVT. LTD., KHIRA NAGAR, MUMBAI.
• M/S. VAM SOLAR POWER LLP., C232, SECTOR 10, NOIDA, U.P.
• M/S. LALITHA ENTERPRISES PVT. LTD., RAMABAI NAGAR, MUMBAI, MAHARASHTRA.
• M/S. INNOVATIVE VASTU NIRMAN PVT. LTD., KAMPALLY, HYDERABAD.
• M/S. DELHI ENGINEERING SOLUTIONS, UTTAM NAGAR, EAST DELHI.
• M/S. PRATYAKSH MACHINERY PVT. LTD., INDORE, MADHYA PRADESH.
• M/S. SUN FLAG IRON & STEEL .CO.LTD., NAGPUR, MAHARASHTRA.
• M/S. ARAM CONSTRUCTIONS PVT. LTD., THIRUCHIRAPALLI, TAMILNADU.
• M/S. CONTROL TECH SOLUTIONS PVT. LTD., PUNE, MAHARASHTRA.
• M/S. MASCOT DYNAMICS PVT. LTD., THANE, MAHARASHTRA.
• M/S. JAGRAMJI PLYWOODS PVT. LTD., YAMUNA NAGAR, HARYANA.
• M/S. JUPITER MARKETING COMPANY, G.B. ROAD, CENTRAL DELHI.
• M/S. PACIFIC ELECTRONICS PVT. LTD., MEDCHAL, MALKAIGIRI, TELANGANA.
• M/S. PRECISE FOUNDATION & CONSTRUCTIONS PVT. LTD., KURLA WEST, MUMBAI, MAHARASHTRA.
• M/S. INFIQUITY AUTO TECHNOLOGIES PVT. LTD., MEDCHALL, RANGAREDDY, TELANGANA.
• M/S. CREDENCE TCECHNOLOGIES, KALYAN NILJE, THANE, MAHARASHTRA.
• M/S. DCC PROMOTERS PVT. LTD., KUMARAN COLONY, SECOND STREET, VADAPALANI, CHENNAI.
• M/S. ESTERN PILING & CONSTRUCTION PVT. LTD., ORISSA.
• M/S. RISHAB LOGISTICS PVT. LTD., NEW DELHI.
• M/S. RADIANT TECHNOLOGIES PVT. LTD., MUMBAI.
• M/S. AMRUTHA TECH SERVICES PVT. LTD., CHANDIGARH.
• M/S. HIRAKUD HARDWARE MART, ROURKELA, SUNDARGARH, ODISSA.
• M/S. NAULAKHA REFRIGERATION, M.G.ROAD, SECUNDERABAD, RANGA REDDY, TELANGANA.
• M/S. S & R CONSTRUCTION PVT. LTD., GOPALGANJ, BALIWAN SAGAR DISTRICT, BIHAR.
• M/S. INFRA PILOT ENGG & CONSTRUCTION PVT. LTD., CHOWDRY NAGAR,VALASARAVAKKAM, THIRUVALLUR.
• M/S. FIBRO GRATS PVT. LTD., LASUDIA MORI, INDORE, MADHYA PRADESH.
• M/S. PRIYA PACKAGING PVT. LTD., TUTICORIN.
• M/S. DANA CORPORATION, BELGAUM, KARNATAKA.
• M/S. EMMBROS AUTOMOTIVES PVT. LTD., BADDI, HIMACHAL PRADESH.
• M/S. EMMFORCE AUTOMOTIVES PVT. LTD., BADDI, HIMACHAL PRADESH.
• M/S. HITECH CORPORATION, MADURAI.
• M/S. UNIVERSAL COMPANY PVT. LTD., VADIPATTY, MADURAI.
• M/S. NEW TECH ENGINEERS PVT. LTD., AMBATTUR, CHENNAI
• M/S. MOTHERSON SUMI AUTOMOTIVES PVT. LTD., ORAGADAM, CHENNAI.
• M/S. VEL TECH ENGINEERS PVT. LTD., KAPPALUR, MADURAI.