SENTHIL KUMAR SG

Senior Management Professional

Manufacturing Operations | Manufacturing Engineering
Strategic Planning | Business Re-engineering

Over 21 years’ experience with impressive success in setting up & directing

manufacturing operations across Automotive / SMT PCB Manufacturing domains
Preferred Location: Chennai / Coimbatore / Bangalore/ Pune
kumarsgsenthil@yahoo.co.in +91-9500104306 / +91-9994443968

Executive Profile Key Impact Areas

Achievement-driven business leader with excellent track record of P&L Strategy
managing complete operations for business and producing consistent top Accountability Planning &
line & bottom line growth of business across the regions
Leadership
A principle executive ‘point of contact’ for the company with
responsibility of ensuring that appropriate manufacturing strategies are
Production/ NPI/ Technology
in place and are acted upon as per the priorities
Plant Transfer
Participated in formulating budgets, planning Opex / Capex and
controlling manufacturing through business excellence philosophy Operations
Excellence in managing technically advanced, cost-efficient & state-of-
the-art manufacturing systems to ensure top & bottom line profitability People Lean
Contributed in ensuring sufficient human, financial, Management/ Manufacturing
technological, informational, quality, automation, process IR
enhancement, HR resources, and material resources are available to
ensure smooth operations Manufacturing Industry 4.0
Administered 6 sigma initiative in plant and developed 3 black belts and 23 Excellence and iOT
green belts; acknowledged with Best Project Award and appreciation by
Global CEO and distinguished tech fellow
Expertise in driving operational cost reductions and infusing change Six Sigma Black Green Field
management as per requirement Belt & Quality Project
Strong skills in liaising & coordinating with Statutory Departments Mgmt. Exposure
and other administrative authorities for issues
Exhibited excellence in devising strategies for quality system implementation,
leading quality improvement projects & conducting audits
Excellent strategic thinking, analytical, management skills with
proven capability in working in international, multi-cultural environments

Education & Credentials

BE (Mechanical Engineering) from Coimbatore Institute of Technology,
Coimbatore, Tamil Nadu in 2006
Diploma in Mechanical Engineering from Government Polytechnic,
Coimbatore, Tamil Nadu in 1997

Career Timeline
Pricol Limited, Visteon Automotive India
Texmo Industries,
Coimbatore as Senior Private Limited, Chennai
Coimbatore as
Lead – Production as Deputy General
Trainee
Manager-Manufacturing

Certifications
1997 - 2000 - Since  6 Sigma black belt
2000 2008 2008  Shingo-By EFESO
Discover Excellence
Cultural enablers
 4 Disciplines of
3 Years 8 Years 10+ Years execution by franklin
covey
 VSM & SM
Selected Achievements Across the Career
Successfully reduced the P&L cost:
o Manufacturing cost from 22.8% to 15.7% of revenue Over last 3 years
o Labour and Overhead cost from 9.8 to 7.4% of revenue Over last 3 years
o CAPEX Investment by 19% from the approved budget through localization, inhouse development, smart manufacturing
technics (Like Cabot, AGV, Indexing heads, auto screwing, etc.)
o Process scrap from 0.73% to 0.45% of material cost through various kaizens and employee involvement
o Repairs and maintenance cost from 0.78% to 0.51% by localization, AMC cost reduction, in-house servicing
o Power cost reduction by 35% by using Wind energy, Solar energy (No capex investment) and Bio mass energy
Attained Shingo silver medallion from Shingo University-USA through employee involvement initiatives, SDWT,
Continuous improvement, Cultural and behavioral improvement in 2019
Accomplished 18 VSM projects in 2018 and achieved 28% capacity improvement achieved; targeting 32% in 2019
Formulated Technology roadmap with industry 4.0 and iOT focus to improve quality, efficiency, material handling,
setup time reduction and data collection and analysis and communication
Single digit PPM: Achieved Single digit PPM (22 to 9 PPM-3 years) and Zero new launch issues in 2018 through quality
road map, Safe launch plan, TPPA for FTT defects and DFM reviews
Implemented 4dX principles and conducted weekly commitment meeting to achieve 1 key lead measure for the year
(Profitability, PPM) – in 2016 & 2017
Installed COBOT, ROBOT, AGV and Indexing heads in plant to minimize man power and to improve productivity
Played a key role in enhancing OEE 71% to 83% and using 16 major losses analysis and actions
Developed manufacturing dashboards for KPI monitoring online and to reduce data collection and preparation time
Handled labor issues and labor unrest without affecting customer delivery and quality

Professional Experience
Since Dec’08: Visteon Automotive India Private Limited, Chennai as Deputy General Manager-Manufacturing

Key Result Areas

Spearheading the entire manufacturing operations activities as per the goals of organization; developing new initiatives
to create annual operating plan (AOP) to support the strategic directions
Planning, organizing, directing, & controlling operations through business excellence philosophy
Managing business operations with key focus on bottom line profitability by ensuring optimal utilization of resources
Supervising end-to-end projects for set-up, expansion, modernization, and finalization of technical specifications
Monitoring Opex & Capex, leading capacity planning, productivity improvements & technical issue resolutions initiatives
Liaising with mgmt. for evolving strategic vision, driving change, and infusing new ideas for next level performance
Ensuring adherence to quality systems, maintaining requisite documents to ensure improvement in process capabilities;
providing guidance and recommending improvements on manufacturing methods to reduce errors
Developing supplier assessment systems, identifying areas of quality failures and taking steps to rectify the system
wide preventive & corrective actions to avoid the reoccurrences
Ensuring adherence to statutory & regulatory requirements as per Visteon global and Indian Govt. standards

Highlights
Products Handled: Instrument cluster, Audio infotainment and PCB
Managing $139 Million (970 crores) annual Production revenue shop floor
Heading 2 major functional areas of assembly and SMT (PCB manufacturing)
Administered 7 key departments including production, Advance manufacturing, Plant engineering, Maintenance,
process quality, continuous improvement and IE & Pursuits
Managing day-to-day operations, supervising 36 direct and 670+ indirect reports
Ensuring NPI from quote stage to part delivery (Quote, DFM, Process design, Equipment ordering, Prove out, Customer
builds and audits, SOP, Safe launch plan, Handing over to Production)
Modernized documentation and accounting procedures resulting in effective management of operations
Steered safety audit and facilitated safe working conditions in shop floor and offices.
Led zero LTC for the last 10+ years Through Loss control tours and safety steering committee engagement
Engaged in SDWT teams to resolve line issue on their own using QCC steps – Teams got 5 external awards
Online LPA tool and evaluating sheet tool to improve Adherence and transparency
TPM initiative which involved work men in machine maintenance and CLRI through “My machine”
Played a key role in attaining ANSI2020 ESD certificate for ESD control compliance
Previous Experience
Nov’00 - Dec’08: Pricol Limited, Coimbatore as Senior Lead – Production

Highlights
Products Handled: Instrument cluster - 2W& 4W
Managed $ 25 Million (160 crores) annual Production revenue shop floor
Managed day-to-day operations, supervising 8 direct and 140+ indirect reports
Responsible for product/process quality of new products and existing products
Responsible for line capacity enhancement, Poka yokes, scrap, process capability
Responsible for TPM, 6 sigma and continuous improvement

Aug’97 - Nov’00: Texmo Industries & Gokul CNC, Coimbatore as Engineer & Trainee

Trainings Attended
Shingo Training Program on the following topics in 2018:
o Three Insights of Enterprise Excellence
o The Shingo Model
o The Guiding Principles
4DX trading by Franklin Covey in 2016
Attended Leadership training for managers by Dale Carnegie
6 Sigma black belt training by Visteon global expert for 6 Weeks in 2016
QMS Training Programs; including IATFTS 16949:2016, ISO 14001, QS 9000, conducted by the Internal and External
Trainers
Six Sigma (DMAIC Methodology) conducted by M/S Satyam Consultancy for 6 months in 2007
Lean Manufacturing Concepts conducted by Fest-tool company, Germany
5 S Concepts
FMEA, APQP & PPAP Conducted by CII
Problem-Solving techniques conducted by CII
TPM by Center of Excellence, Bangalore
Business Score Card (BSC) by Pricol Ltd. – 2 days

IT Skills

MS Office (Word/ Excel/ PowerPoint), SAP, Minitab and Internet Applications

Personal Details
Date of Birth: 14th April 1979
Languages Known: English and Tamil
Present Address: 278, Velli Vedhiyar Street, MIG, NH-1, Maraimalai Nagar, Chennai -
603209, Tamil Nadu
Permanent Address: 3/C, Malar Illam, Bharathi Nagar First Street, Uppilipalayam (P.O),
Coimbatore, Tamil Nadu