SARATHBABU MUTHUSAMYPlot No:161-A, Door No 4, Maruthi Nagar, Madambakkam, Chennai-600 126, T.N, INDIAEmail : - sarathm77@gmail.com Mobile No : +91-9543992170/9884072321Pass Port No. Z2323317 ; Expiry date : 05/08/2022Nationality : INDIAN, Languages:Tamil,English & French (Basic communication)Skype : sarath.babum77

OBJECTIVE :

To obtain Head Level Position in a company for Operational Excellence (Six Sigma Black Belt) /QMS

& EMS /Supplier and Process Quality / Manufacturing Operations/ New Product Development/ Vehicle

Management / Logistics/ Purchase / Supply Chain / Warehouse & Inventory Management / Business

Development / Spare parts sales that will allow me to grow along with the company.

HIGHLIGHTS :

Six Sigma Green & Black Belt – DMAIC approach, Project training & Execution

Operational Management – Review targets & identifying projects to maximize the profit

IRCA Certified Auditor (Certification No 6004973) for ISO 9001:2008 & ISO 14001:2004

Internal Certified Auditor for ISO/TS 16949 & Knowledge in TQM/ TPM

Marketing & Sales – Market Research, Market demand, Sales Target & Review

Logistics – On time delivery, preventive maintenance of vehicles and transport cost reduction

Rental Business Development – Genset/Crane/Forklift/Trucks and special equipments

Purchase , Warehouse & Inventory Management – Process Optimization & Control

Spare parts Sales – Minimum level inventory and Sales process improvements

Analysis Methodology – Problem solving, Risk analysis , PDCA & DMAIC

Project Management – Planning, New Product Development, Production Part Approval Process

Customer Handling – Claim Handling, Problem solving, Customer Return Material Analysis

Warranty – Returned part analysis , improvements and cost recovery

Supplier Quality Assurance – Incoming Quality , Supplier Monitoring & Improvements

Supplier Development / In-Process & Out Going Quality

Manufacturing Operations – Productivity, Automation, Cost reduction & Continual Improvement

Process Enhancement / Cost Reduction / Team Management / Risk Management

EXPERIENCE:

Bachelor of Engineering (B.E ) in Mechanical with total 16 + years experience

- 12 Years - Quality Assurance in Automotive Ancillaries and Manufacturing Industries

- 4 Years in abroad – Business Excellence in Sales & Service industry by handling Lean

six sigma / QMS / EMS / Safety / Business development/Purchase/ Warehouse/ Inventory

Control/ Projects executed on Installation process, Spare parts division , Supply Chain and Sales

1. From Apr’2011 to 31st Mar’2015 : (Overseas Experience 4 years)

Worked as a Manager–Business Excellence in Matforce, Dakar, Senegal ( West Africa ) under

The African Management Services Company (AMSCO). It is a United Nations Project, which provides

expatriate managers, funded and training to African Companies.The below assignments were

handled during my service under the scope of Operational Excellence as a expatriate.

- Management System – Quality, Environmental and Safety

- Lean Six Sigma – DMAIC and Statistical tools Training

- Project Execution – Installation of GE/Aircon, Spare parts operations,Garage improvements,

Maintenance Contract improvement, Improvement on Import and Export

- Customer Satisfaction Process and Suggestion Scheme

- Cummins Quick serve Champion to improve customer satisfaction on GE business

- OEM Warranty Support ( Hyundai,Cummins and other customers )

- Internal Vehicle Management – Staff and Exploitation Vehicles (120 Nos)

- Business Development-Rental Sales ( Internal and External Customers)

- Local Purchase – Ontime delivery and Cost reduction on Standard and project materials

- Warehouse – Material Control and ontime delivery through FIFO

- Inventory Management – Inventory Optimization and managing minimum level inventory

Matforce is one of the leading Multi product-Sales & Service Organization and energy

production in West Africa . It is certified for QSE (ISO 9001:2008 & ISO 14001:2004 ) by DNV

and implemented Lean six sigma and excellence program in all business process.

Senegal Region : Corporate office and operations in Dakar (Faidherbe / Belair / VDN ) and

operates in Regions- THIES, TOUBA, ZIGUINCHOR, SAINT LOUIS, TAMBACOUNDA et KAOLACK

Other Countries : Guine Conakry, Guine Bissaou, Mali, Gambia, Niger and cote d'ivoire

Business Activities :

Equipment Energy ( Cummins Genset sales, installation and maintenance )

Production Energy ( Power plant set up and energy production / Solar Energy)

Telecommunication networks ( Power source for Sonatel, Tigo and Expresso)

Air conditioning equipment ( Airwell brand aircondition sales , installation and maintenance)

Heavy and light vehicles ( Sales & Service - Hyundai/Mazda/ JMC/ Dong Feng )

Agriculture and Hydraulic products ( Hatz ) / Mining equipments ( Cummins & Hyundai )

Matforce Technology – Solution (HUAWEI Mobiles Sales & Service / UPS sales & Service )JOB CONTENT

Head - Business Excellence & QSE :-

Corporate Head of Continuous improvement process (Quality, Environment and Safety )

Key contact person with DNV France for the Audit, Actions including payment process etc.,

Executed Lean six sigma projects and Trainings- Lean six sigma, DMAIC and 7 QC tools

Conducted verification Audits on Lean Six Sigma Control phase of implemented actions and report

Co-ordinated for Monthly Review – Sales , Operational and Supporting departments

Reviewed Business target and identified projects to maximize the business profit

Monitored each department KPI and Improved by structured way of analysis

Acted as a Team Leader for Customer Satisfaction and Suggestion Scheme process

Visited to major customers and conducted Satisfaction Survey and Voice of Customer

Ensured Internal System Audits on QSE Management system and Process audit

Facilitator of campaign program to improve business in different time interval

Risk analysis for new business or project based on top management instruction

Visit and Status Report - Projects and Power plant based on Top Management direction

Implemented 5S Audit System and Co-ordinated for Management Review Meeting .

Head - Business Development( Rental ) :-

Ensured Business improvements on Rental ( Genset, Trucks and Handling Equipment )

Developed process and procedures / Prepared Business strategy and Budget report

Prepared SWOT anaysis report / Identified Market demand and customers with different segment

Finalized Rental Cost based on market strategy with competitive quote

Monitored and improved the utilization of Rental equipments - minimum 85 %

Reviewed and Authorized all the rental contract agreement (Short Term)

Ensured ontime delivery of rental equipments to customer with safety measures

Ensured the Inspection of equipments at the time of delivery and reciept of equipments

Reviewed and approved Sales invoices into ERP system ( X3 ) and Updated customer data base

Prepared Monthly Sales report and action on Continuous Improvement

Monitored Customer Satisfaction level and actions on Continuous Improvement

Negotiated with customer to finalize the quote and decision on contract agreement

Prepared Market study report with different Segments and proposed for new investment

Visited customers regularly and provided solutions for big projects for long term Contract

Negotiated for Temproary contract agreement with other society for the short term rental if

customer need special equipments for long term until arrangements of our equipments

Preventive and Break down maintenance of rental equipments / Ensured critical spares

Head - Local Purchase ,Warehouse and Inventory Management :-

Developed effective system and procedures to ensure ontime delivery to internal customers

Identified minimum 3 supplier sources for standard and project materials

Reviewed and Approved the New Supplier and service provider in ERP based on evaluation

Reviewed Supplier and service provider performance report and Actions

Negotiated for the best quote from suppliers based on Monthly material requirements

Managed order placement through shared business based on the cost and quality of product

Conducted weekly Internal meetings with service and project team for delivery & quality issues

Reduced Purchase Cost 30 % by comparing the study between local Vs international suppliers

Created Artical code and updated cost in ERP system

Updated and Released Purchase order in ERP system on daily basis

Ensured Material receipt, Quantity verification, Issuance, document control and entry in ERP

Ensured material arrangements and cleanliness of warehouse

Raised Non-conformity Report on supply issues ( Shortage or Excess quantity, packing damage,

Specification issues and physical damage etc.,)

Monitored and Ensured the effectiveness of Corrective action by suppliers

Monitored the Purchase order’s Closing status in ERP with appropriate documents in case of direct

delivery to the project sites by the supplier based on our request

Negotiated with suppliers to take back sleeping inventory (dead stocks ) and Returned materials

from projects to minimize inventory and space saving.

Prepared Annual budget and ensured right resources to achieve the objectives.

Placed Order based on the stock availability and cutomer payment status of projects

Maintained Minimum level inventory and work space organization in the ware house

Followed safety and environmental measures in the warehouse and material handling

Followed FIFO system and Implemented of Kanban visual management in Warehouse

Executed Annaul Inventory along with Management Controller and team

Organized training on Quality , Environmental aspects and Impact , FIFO, Handling of Non-

Conforming product, Minimum level inventory, Material Safety, Employee’s Health and safety

Closed the inventory gap between ERP system and Actual stock

Prepared and Submitted Monthly stock status report with aging of materials.

Head - Vehicle Management and Transport ( Inbound and Outbound Logistics) :-

Developed effective system for vehicle Management and transport management

Ensured government regulation of all staff vehicle-51 Nos , service vehicle-34 Nos, Rental cars -

64 Nos, Handling Equipments-3 Nos and 2 wheeler-34 Nos based on effective monitoring system

( License, Insurance and other requirements )

Arranged Temproary insurance for company vehicles during neighbour country visit

Organized preventive and breakdown maintenance of all vehicles as per the schedule

Monitored and Reported maintenance cost of company vehicles for the Management decision

Prepared weekly report for the running Kilometer of vehicles and conditions

Authorized the quote for internal vehicle service and repair if less than or equal to 3500 USD

Monitored all service vehicles status through GPS , anlysed abnormality and Issued warning

letter to improve employees and equipment safety

Initiated actions during abnormalities on Vehicle Management Rules through Management support

Handled Accidental Insurance claim , recovery and decision to repair or dispose the vehicle

Organized Transport based on the request from Internal Customer with appropriate information

Circulated the vehicle avaialbility status to all internal customers on daily basis

Monitored and Improved ontime delivery based on the delivery commitment – 90 %

Prepared Annual budiget and achieved Financial objectives

Monitored fuel card Limit based on the kilometer usage Vs standard fuel consumption

Monitored and Authorized Transport allowance for each local and outside trip

Managed Corporate Bank Card with 3500 USD limit for the transport expense and regularized in

frequent interval if the card balance is reduced less than 1000 USD

Organized regular driver’s meeting and given instructions on daily planing (MILK RUN), delivery

issues, difficulties, safety issues and motivation

Arranged materials with identification and aging through monthwise color coding sticker

CAREER PATH WITH NOTABLE CONTRIBUTION:

Received excellent feedback from DNV during QSE recertification in 2012

Sustained Excellent QSE Management System Based on Internal and External Audit

Implemented common QSE Management for other affliates and branches

Implemented Customer Satisfaction Process & Suggestion scheme

Implemented Lean six sigma Projects – GE/ Aircon Installation, Reduced sleeping inventory and

Sales improvements (Spare Parts) , Cycle time reduction in Garage, Maintenance contract

Implemented System for Transport & Vehicle management

Implemented Cummins Quick serve program to improve GE business in West Africa

Marketing & Sales – Assisted Sales Departments ( Light and Heavy Vehicles/

Generator/Aircondition/ Mobiles ) to increase Sales through Training and Dealer’s development

Local Purchase – 30 % Cost reduction through Import materials, Effective system

implementation, Achieved 90 % of ontime delivery for standard service materials within a day

from the request date , 85% of ontime delivery for Project Materials within 3 days for local and

minimum 3 weeks for imports from the request date and minimized inventory cost by 50 %

Ware House – Space utilization, Rack arrangements with good FIFO, Created Weekly automatic

report on inventory with aging in ERP (X3), Inspection control and safety , Visual Managment

with color coding sticker for monthwise tracking and KANBAN for standard materials.

Supply Chain – Reduced lead time for Imports and Exports, Smooth Operation in entire cycles

Training – Auditing Skills / Lean six sigma / DMAIC / Problem solving tools ( 7 QC )

New Rental Business ( Marketting & Sales ) – New Business Setup and System, From 30 % to

80 % of equipment utilzation on Rental Sales, Improve business Profit by 50 %, Improved

customer satisfaction, Created competitive quote, Study proposal on Market Segments

Inventory – Implemented effective system to reduce time on Annual inventory

2. From 1st Sep 2008 to 31st Mar 2011 : ( Chennai – India )

Worked i n Perlos India Ltd from Sep’08 to Mar’11 as Senior Engineer (Professional Grade)

Perlos (Liteon Mobile ) is one of leading Supplier of Nokia. It is a manufacturing of mobile

accessories .(Sheet metal,Injection Moulding,Assembly,Painitng) The production facilities are in Asia,

Europe and America and headquartered in Finland. The company is taking care of Injection

Moulding, Punching, Painting, Tampo Printing & Assy of Mobile accessories. It is certified for ISO

9001, ISO 14001& ISO 18001(OHSAS)

JOB CONTENT

In charge-SQA (Supplier Quality) from Oct 09 to Mar 11

Supplier evaluation and approval process with Sourcing team / Incoming Quality

Monitored and Reviewed Supplier performance (PPM/DPM/8D/Production Line feedback)

Executed QMS / EMS and process audit at supplier end

Ensured Corrective and preventive action- supplier 8 D report

In charge- Customer QA & Assy QA from Sep 08 to Sep 09

Reviewed internal and Customer end rejection PPM and actions in PQ meeting

Organized Monthly meeting with Customers and actions towards improvement

Reviewed and Authroized Kappa test qualified line inspector for visual quality

Key window person – PQE ( Project Quality Engineer) and new product approval

Internal Auditor, 5S champion,Corrective&preventive action on Customer end & Field rejection

CAREER PATH WITH NOTABLE CONTRIBUTION: Successfully launched new product initial line qualification and customer approval

Excellent operation control in process and inspection and Supplier performance

Reduced Suppliers PPM in Die cut parts 8000 PPM to 1000 PPM

Successfully executed 6 sigma Green belt project – COPQ reduction of Kingston A cover

3. From 4th Oct 2006 to 30th Aug 2008 : ( Chennai – India )

Worked in Asahi India Glass Ltd (AGC Japan) as Section Manager-Customer QA

AIS is an Auto Glass Manufacturing and its Sub Assy;

HMI,Ford India,HML,Toyota,TATA Motors-South Customer

Maruthi & Honda – Supplying of Tempered glass and assy from Chennai plant

ISO/TS-16949: 2002, ISO 14001, Deming Award (TQM) certified and Practicing for TPM.

AIS achieved and sustaining HMI Prestige Award 5 STAR and Ford Q1 Award.

Tier I Supplier of Ford, Hyundai,HML ,Toyota, TATA, Maruthi and Honda - 85 % Market Share

JOB CONTENT

Handled Customer Claim and ontime submission of root cause study report

Action taken internally to sustain and reduced customer line PPM and internal PPM

Visited customer in frequent interval related to quality improvements

Ensured On time submission of ISAR/Revalidation report /SDS / PPAP

Conducted Verification audit for the effectiveness of actions on Customer complaints

Handled Engineering changes, VA/VE proposal, Handling of Warranty issues

(OEM and Commercial ) Warranty returned part analysis and report to PD team for New project

Prepared and executed the actions for the readiness on TQM/5 Star/Ford Q1 Audit certification

CAREER PATH WITH NOTABLE CONTRIBUTION: Reduced Auto glass rejection at customer site during sequence & Warranty issues ( 8 % to 2 %)

Achieved Excellent feedback from all OEM on 100 PPM methodologies and sustainability

PDCA approach – Eliminated transit breakage & Edge damage of windshield

Successfully achieved – TQM / HMI 5 Star / Ford Q1 certificate

4. From 11th May 2005 to 30th Sep 2006: ( Chennai – India )

Worked in Motherson Automotive Technologies & Engineering (A Division of Motherson Sumi

Systems Ltd), MATE-IV as a Sr Engineer-Quality Assurance. M A T E is an Automobile Plastic

Components Manufacturing & Assy. It is a Tire 1 Supplier of Ford-India, Ford –

Europe, Hyundai Motors, General Motors, Toyota, Maruthi, Air International and etc.,

MATE-IV is a Assy unit for FORD FIESTA ( Instrument Panel Assy & Console assy)

JOB CONTENT

Project Quality Assurance from Feb 04 to Dec 05

New product development - Ford Fiesta dash board , Console, Hand brake bazel & Gear bazel assy

Project Quality,Trial Qualification, Sample approval and dimension and Appearance

New Project all the parts - Tool Buyoff sample qualification & Approval

Reviewed and Approved PPAP for all Import /Local Supplier during project phase

Acted as a Supplier Technical Assistant Engineer (STA) on High Impact supplier

QMS / EMS & Supplier Quality Assurance Jan 05 to Sep 06

Implemented QMS / EMS and Ensured sustainability of the system through regular internal audits

Initiated to Set up Policies , Objectives and Policy deployment with Top management

Prepared QMS documentation, Records and format development, implementation & Control

Prepared and Conducted Internal audit and Actions on Audit result ( Internal / External )

Organized for Management Review Meeting with the support of Top Management

Ensured Control of documents and records with amendment history

Acted as a Team member of internal assy line issues and actions

CAREER PATH WITH NOTABLE CONTRIBUTION:

Successfully Implemented New Plant Assy line set up/ POKA YOKE Systems in production line.

Participated on Line Layout, Material Flow, Cycle time study, Kanban for inward materials and Line balancing

Achieved New project part approval (PSW sign-off) - Ford FIESTA Car-IP Assy & Console Assy

Implemented Level 3 Documents for Assy Process in the new plant (MATE-IV)

Developed High impact suppliers - Mutual Industries Ltd - Plastic components & Hydro Graphic Finishing with Japan

collaboration & SVC- Sheet metal & Robo welding of IP Assy

5. From 1st May 2004 to 16th May 2005 : ( Chennai – India )

Worked in INJECTOPLAST (LOHIA GROUP) as a Engineer-Quality Assurance which is located in

Irungattukottai, Sriperumbudur Taluk, Kanchipuram District, Chennai. It is a manufacturer of

Automobile Plastic Components; It is a ISO:TS16949:2002 certified Company by DNV.

It is a Supplier of Ford-India, Visteon, PHC, Lumax Samplip and Rane Madras & Pondy.

JOB CONTENT

Co-ordianation with Corporate M.R (Quality System ) in documentation part of ISO: TS16949

Internal Quality Auditor for ISO/TS16949:2002

Customer Representative for SL Lumax and PHC

Process Audit on Injection Moulding process

Reduction of Internal and External PPM

Corrective and Preventive Action against Customer complaints by using 8D and 3D Report

Document Preparation and Updation – PFD,PFMEA,Control Plan, Calibration Records,

APQP,PPAP, ISAR and MIS data for Quality department

Incharge of Dock Audit, Member of CFT and Auditor for system adherence in QC area.

CAREER PATH WITH NOTABLE CONTRIBUTION:

Successfully contributed for the Certification Audit of ISO/TS16949:2002

Reduction of Internal PPM trend – Injection moulding process along with CFT

Implemented Visual Aids for all the components with Defect and Effect Matrix

Reduction of Customer Complaints

Team Member – Successfully Reduced the Warpage rejection of Tank Inlet

6. From 22nd July 2002 to 25th Feb 2004: ( Chennai – India )

Worked in Silicon Valley Auto Components (P) Ltd, as a Senior Engineer-QA

SVC is an Indo German Collaboration Company, manufacturer of sheet metal pressed and welded

components; it is a ISO/TS-16949: 1999 certified company by UL. It is a Tire 1 supplier of

VISTEON , CATERPILLAR,SAME DEUTZ FAHR,VOLVO ( Automobile Industries )

JOB CONTENT

Acted as a Customer representative for Visteon Automotive

Monitored Internal and Customer line rejection PPM and actions

Conducted Cp and CpK study , Internal Audit and process audit

Prepared and Received Ontime approval of PPAP

Ensured MSA studies, Calibration, Actions on Customer audit findings and Line inspection

CAREER PATH WITH NOTABLE CONTRIBUTION:

Implemented Error proofing on Press tool for avoiding quality issues

Ensuired Ontime Submission of PPAP and APQP approval process and PPAP Samples

Ensured Shop floor 5S & SPC control for special characteristics

7. From 12th June 1999 to 16th July 2002: ( Chennai – India )

Worked in Automotive Ancillary Services (P) Ltd, Thuraipakkam, Chennai-96 as an Engineer-QAAAS is a renowned company in producing sheet metal pressed and welded components; it was a

QS-9000; 1998/ISO 9002:1994 certified company by BVQI. AAS was a Tire 1 supplier of FORD ,

GENRAL MOTORS, BRAKES INDIA, ASHOK LEYLAND , DENSO INDIA , RANE , DENSO

KIRLOSKAR , AMALGAMATIONS REPCO ( Automobile Industries )

JOB CONTENT

Inprocess inspection of sheet metal pressed components ( First off/In-Line/Last off)

Gauge inspection, internal calibration, Stage drawing inputs for new development

Assited PPAP document preparation ( PFD/PFMEA/CP ) and New development support

Conducted and action implemented on 5S Audit

Acted as a Interim for production line during production incharge absence

Ensured press tool set up and approval process and Initiating POKA-YOKE

Maintained Records of Line inspection and Assited for ,APQP preparation

Monitored Online SPC for the special and critical parameters and control

CAREER PATH WITH NOTABLE CONTRIBUTION:

Supported for Ford ikon sheet metal parts development - Pp and Ppk & PPAP

Successfully faced QS-9000, TS16949:1999 Certification Audits and Routine Customer Audits

EDUCATION:

07.1995 – 07.1999 Bachelor of Engineering (B.E ) in Mechanical, Thangavelu EngineeringCollege, Madras university, Chennai,T.N India

06.1993 – 06.1994 +2 Maths & Science , M.H.S.S, Tamil Nadu State Board. Karur,T.N. India.

06.1992 – 10th Standard , C.S.I Hr.Sec School, Tamil Nadu State Board. Karur,T.N. India.

TRAININGS & COURSES:

1999~2002 Internal training – SPC, PFD, PFMEA,CP,PPAP, MSA,5S

08.2002 Internal Auditor-ISO / TS 16949 , Chennai, T.N. India, 2002

08.2005 IMPLEMENTING EFFECTIVELY APQP/PPAP, Chennai,India,2005

01.2006 BASIC OF POLYMER TECHNOLOGY , Chennai, India,2006

05.2006 Internal Auditor-ISO / TS 16949: 2002 , Chennai, T.N. India, 2006

05.2006 Internal Auditor-ISO 14001:2004 , Chennai, T.N. India, 2002

10.2006~08.2008 TQM-Prof. Tsuda from Japan, TPM, 5 STAR audit & Ford Q1

04.2007 Long term Managerial training on soft skills, Uttaranchal,UP,India,2007

08.2009 SIX SIGMA Green belt project affidavit, Chennai, T.N, India,2009

05.2012 LEAD Auditor Certification ISO 9001:2008, Chennai, T.N , India , 2012

05.2012 LEAD Auditor Certification ISO 14001:2004, Chennai, T.N , India , 2012

04.2012 HYUNDAI Dealership Enhancement Program, South Africa

04.2013 CUMMINS QUICK SERVE QUALIFICATION, South Africa Team

08.2015 V-Skills Certified SIX SIGMA GREEN and BLACK BELT

SOFTWARE SKILLS :

Microsoft Word, Excel , Power point and ERP Client X3 ( Accounting Package )

REFERENCES:

1. Mr. T.Gourishankar - Lean Six Sigma Black belt –TGS Management Consultant

Chennai,India. Mobile no : +91-9840061260. Email : gouritg@yahoo.com; tgsmc@vsnl.net

2. Mr. Hariharan , Head– QA , PERLOS INDIA LTD.

Mobile no: +91-8056023040. Email: rsh2001@rediffmail.com

DECLARATION

I hereby the above mentioned details are true to the best of my knowledge.

Place: Chennai, T.N, INDIA.

Your’s Truly,

(M. SARATH BABU)