S.

KARTHIKEYAN
30, Rue De Marchienne, Charleroi - 6000, Belgium
Contact No.: +32 478688822 (Belgium)

E Mail: nayek2k@yahoo.co.in

Seeking career enrichment opportunities in Operations, Industrial Engineering, Project

Management with an organization of repute in the BPO/ ITES sector
SNAPSHOT:

An incisive professional with nearly 9 years of Leadership experience in Assembly,

Manufacturing & Industrial Engineering, Design & Development, Shop-floor CNC production & Quality Control
in Motor Company, Automobile industry and presently in Worlds Largest earth moving Equipment
Manufacturer. Ability to develop detailed project plan & scoreboard to monitor progress & flag issues, &
develop detailed procedures, flowcharts, and measurement framework to smoothen the process. Conversant
with CAD software viz., AutoCAD, Pro/Engineer (Modeling, Detailing, & Assembly). Skilled in CNC Machine
Programming, Operations Tooling & Maintenance, NC Milling, & Machining Centers & Submersible Body TIG
Welding production Shop. Expertise in end-to-end project planning and implementation from scope
management, to activity sequencing, effort & cost estimation to quality management in adherence to
guidelines and norms. A Change Agent & Turnaround Catalyst with proven track record of utilizing a processoriented approach towards the accomplishment of cost, profit, service and organizational objectives. Holds the
distinction of steering numerous modernisation, industrial automation and technology up-gradation projects for
diverse industry segments. Adroit at Quality Control and Inspection. Knowledge in Six sigma Black BeltDMAIC,DFSS

&ISTRIVE,

TPM,

ISO

9000,

5S

&

KAIZEN.

Excellent

leadership,

planning,

analytical,

troubleshooting, inter-personal, techno-commercial and negotiation skills with proven ability in building
relationships with government departments, upper-level decision makers, technology partners and external
agencies.

FUNCTIONAL SKILL SET

KPO OPERATIONS
Process Management
Operations Management
Transition Management
Project Management
Quality Operations
Team Management
ENGINEERING OPERATIONS
Designing Operations
Process Enhancement
Cost Optimisation & Control
Quality Assurance
Documentation
Team Management

Managing detail designing of products. (Conceptual design, detailed calculations, component selection,
plan drawings, material selection, part drawing).
Preparing technical specifications, scope & deliverables, estimates and BOQ based on requirements
generated during detailed engineering of the project .
Following up with the technology for process stabilization, steady state operations, process transformation
& continuous process improvements.
Overseeing continuous improvements in service levels by benchmarking best practices.
Ensuring CTQ closure: Productivity-Capacity Based Turn Around Time (TAT) through Time studies &
Capacity Planning and Accuracy Base-Lining.
Undertaking all steps for ensuring uniformity in the process understanding at the clients and the
organizations end.
Assembly Planning. - Mostly of dealing the NPI (New Product input) by planning the Materials/Required
Manpower/ and TAKT time for operation.
Analyzing the training need & accordingly preparing training modules for imparting training on soft skills/
product/ process.
Developing project planning, training schedule, training implementation teams, coaching them in
delivering the training, monitoring training progress, &updating the stakeholders on a weekly basis.

Reengineering the process after transitions to eliminate any bottlenecks & save cost of extra efforts.
Following through the transition till the finishing point and handed over the same to operations by proving
the inputs during Post Implementation Review.
ORGANISATIONAL SCAN

Since Jul03: SATYAM BPO as Senior Lead Engineer

(Core Member to build & develop the team from Startup and established many processes)
(Working for Fortune 100 Client-GOSSELIES- CATERPILLAR BELGIUM) - Asst Operations Manager
Role:
TRANSITION

Fore fronting all operations for managing the Transition Travel.

Implementing & overseeing transition phases: Pre-Transition, Transition Phase & Post-Transition Phase.

Designing, procuring & deploying technology. Finalizing SLAs & contract Parameters.

Revamped the process and led team towards achieving Business As Usual (BAU) by getting VOC.

Undertaking testing to identify risk & their mitigation phase.

Conducting line balancing and Line loading.

Setting up targets & goals for the process setting and maintaining CTQ, CTP targets for the process.

Undertaking responsibilities of removing unnecessary procedures in process for efficient functioning.

Generating weekly/ monthly MIS & OEE reports pertaining to process and productivity.

Conducting performance appraisals & interviews to ensure motivation of the team members for incentives.

Implementing call monitoring/ calibrations for quality control and ensuring that quality & services
parameters are met at all levels.

Conducting continuous audits on MIS to ensure compliance and sound functioning of the process.

Ensuring the teams adhere to all the quality tool and procedures.

Pivotal in Audit team related to ESCM Level 4 Certification and maintained 100% Quality in 5 different
processes by guiding team with Six Sigma Methodology and documenting records and maintaining and
preparing Risk Mitigation Plan along with Deloitte team.

Actively participating in execution of quality improvements projects for continual improvements.

Continuously monitoring the process with Six-sigma methodology.

Billing and Budgeting on the revenues and monthly presentation to Finance team and client

Preparing Business case for new business opportunity.

Shop floor Ergonomic controls/suggestions based on VMF and simulation and Line support activities.

Complete NPI Procedure Documentation and Follow-ups with Releasing ,Purchase and Logistic teams.
Highlights
As Senior Method Analyst

Achieved 112% Productivity & 100% Quality in CDSA.

A core member of Six Sigma Project for 'CDSA Standards Quality Improvement' to reduce the Defects
Level from 0.05 to 0.001 DPU.GB trained (Externally & Internally)

Created:
o
Manual on Engines as a Part of 'Process Improvement.
o
Engine Animation for an Engine Assembly.
o
Designed Logos & Punch lines for team advertisement.

Developed macros in CDSA and achieved savings from 32 to 14 strokes.

Successfully designed & produced T-shirt for the team.(Special Initiative POB)

Holds the distinction of being felicitated twice with Pat on the Back for Best performance in giving
production & Quality and for taking special initiatives (Internal Customer Delight).

Assisted the onsite coordinator during the transition phase using the SMART methodology
As Team Lead

Pivotal in risk mitigation plan for Static File Process & for CAT MEC team.

Conducted root cause analysis and received appreciation from Assembly planning manager for the
good work shown in time savings from 5hrs 50 min to 5 hrs 6 min, there by saving manpower of 3
assemblers.

Recipient of:
o
Quality Guru Certificate by passing the exam conducted by Nipuna Quality tem
across the organization.
o
Certificate from Red Cross for Blood Donation & motivated team to participate.

Instrumental in:
o
o

Completing the 3 months Transition at Client location and received Appreciation

directly from Client.
Leading and managing the offshore team in achieving and exceeding client SLAs.

Supported & mentored in 9 processes within a short span of time.

New team recruitment and induction to team.

PROJECTS INVOLVED
Projects Handled: (Engines, Equipments, Motor graders, power train and tractors, Excavators)
(Gained Leadership & Management Experience and Client Relationship to Lead a Team in India and Overseas)

Industrial Engineering Assembly Planning: Involved Value-Added Industrial Engineering activity (Methods
Study, Time Study & Assembly Information Systems) for Caterpillar MossVille, Lafayette and Greenville
Engine Division (4 Months in Mossville location-USAtwice visited)

Design & drawing Changes-Visual Aids: Involved in the Design Changes & drawing Changes using 3D
Software Viz Mockup, Vis view & Adobe Photoshop. Created visual Aids for Assembly operations (6months)

Part Location Rationalization: Involved in change of Bill of Materials (BOM) from Racks, Hutch and
relocating in the desired location in the station and changing Building location (mention duration).

Engineering Change Management: Involved in engineering changes in parts of the Engine such as
attachment, removal as per the NPI & Attachment using team Centre and changing the BOM, Description &
Drawings & Plant Layout and Ergonomics for Tooling Dept and Assembly section.

Static & Base Hour Calculation: Involved in calculating and doing root cause analysis for the given Engine
model and to estimate the base hours and updating it in BHMF.

Business Development Team: Pivotal in Business Consulting group by updating the sales & Marketing
related work. Keep track of Client Visits and feedback from clients by capturing & updating in sales Funnel.

Report Generation: Assisted Wheel Loader and Equipment team in Report Generating and supporting them
during urgent work in areas like time study

Simulation: Simulation study for Engine Assembly Line. Doing Analysis and Finding Bottlenecks.

ODS-Time Standards: Successfully completed the Pilot for Gossilies with ODS.

Cost Estimation : Worked on Cost Estimation-Analysis for Motor Grader-Decatur CAT for 6months.

Engineering Change Co-ordination: Assembly Planner& Coordinator for CAT Belgium Excavators Engg
Co-ordination Team

Jan 02 - Jun 03:

L.G. Balakrishnan & Bros as Assistant Engineer

The Key Result Areas (handling CNC Machine Shop, heat treatment, Tooling and TPM)

Distinguished efforts towards executing the design operations encompassing research, development &
testing of mechanical & hydraulic based special purpose machines.

Accurately and efficiently performing computations and aiding the design process by permitting the
modeling and simulation of new designs.

Working on CNC projects & managing operations including planning, scheduling & execution.

Identifying scope for modifications in various equipments for reducing conversion cost of per unit.

Executing cost saving and energy saving techniques/ measures and modifications to achieve substantial
reduction in O&M expenditures and work within the budget.

Establishing quality standards, implementing stringent quality control systems to enhance quality of
products. Involved in developing various documents and procedures at par with ISO 9001-2000.
The Attainments

Designed CNC components using CADD/ PRO-E 2001.

Member of TPM activities, Documentation preparation in ISO activities.
Acted as a Team leader for maintaining 5S & TPM team.
Worked on Auto CADD 2002, PRO-E 2001 & ISO 9001:2000.

Nov 99 - Jan02 worked with Aqua sub Engineering-Unit-I, II, IV (Texmo Group) as (CNC
Programmer/Operator/Shift In charge)
Role:

Conducting classes in CNC programming & Operation for fresh diploma holders.

Undertaking designing of fixtures for Shaft drilling in CNC milling machine.

The Attainments

Introduced short programming techniques-Using Macros.

Designed aluminum cooling fan-using PRO-E.

Achieved reduction in manpower & enhancement in production activity & in CNC Maintenance.
May 99 Oct 99: Commenced career with Coimbatore Compressor Engineering Company as a
Trainee Supervisor in Vendor Development and Sales Department as a part of Prime Ministers
Special Entrepreneurial Program

PROFESIONAL AFFILIATIONS
Alambana M7 team-Joined with Satyam team and worked in schools on weekends.
(ICON Award Holder from Chairman-Im Celebrity Of Nipuna)
Sarang team- Conducting cultural programs and team parties.
CS transportation team- To arrange Cabs for team members effectively and cost cutting.
Emergency Part Team- Attended training for Rescue during fire accidents and natural calamities.
Escm Auditing team-To be an Internal Quality Auditor (Worked during e-SCM level 4

TRAININGS ATTENDED
Six Sigma GB training on ISTRIVE

Communication and presentation

Methodology of Satyam.
skills & Business Writing Skills.
2 Training program on Leadership

American Culture and Ethics &

skills-IMPACT Satyam Leadership
French Language Basics.
School.

Stress Management Workshop.

1 day training on Personality

Conflict Management.
Development Program.

Time Management.
Quality Management System.

Lean Engineering.
CERTIFICATION

ISI Six Sigma and Statistical Quality Control.

Project Success Method-From YCA and Project Management Institute.
IIIE - Association Associate Member (Private).

TRAINING ATTENDED
Attended training at:

ELGI Equipments Ltd., Singanallur (Oct 97-Nov 97).

S&T Workshop, (Southern Railway, Podanur May 98-Jun 98).

PSG Industries (Aug 96-Apr 99) Foundry & Metrology Lab

IT SKILLS
CAD

AutoCAD, Pro/ENGINEER, ANSYS,FACTORY CAD

CAM

CNC Milling, Turning and Machining (Programming)

Languages

C++

Packages

MS Office

Mainframes
& Factor AIM.

AIS, CDSA, EDS, Lognet,CAPP+, Vis view, Adobe Photoshop

ACADEMIA
2007
Engineering,

B.Tech (Industrial Engineering) from Indian Institution of Industrial

Mumbai

1999
Diploma in Mechanical Engineering (3 Years), First Class, PSG
College of Technology,
Coimbatore
2003
Hyderabad

Course in Statistical Quality Control from Indian Statistical Institute,

1999

Course in Automobile Engineering for 1 month

PERSONAL DOSSIER
Date of Birth

14th November 1980

Passport Number

E 7945778

Permanent Address
:
Annur via, Avinashi TK,

25A,

Kollan

Thottam, Pillaiappanpalayam post,

Coimbatore - 641653, Tamil Nadu