569, Park Road (Res.) Anna Nagar West Extension (Mobile)
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1 T.KUPPUSAMI Tel : (Direct ) Flat No: E, Visalam (Office) 569, Park Road (Res.) Anna Nagar West Extension (Mobile) Chennai kuppusami@hotmail.com 1 POST GRADUATE METALLURGIST About 32 years of total experience DIVISIONAL MANAGER Sales & Marketing HINDUJA FOUNDRIES LIMITED (Formerly known as Ennore Foundries Limited) CHENNAI A dynamic team spirited individual recognized for leading manufacturing and quality teams apart from development and other management activities in reputed Foundries CORE PROFESSIONAL STRENGTHS Manufacturing of castings Quality Control Quality Assurance Development of New Processes Development of New Products Commissioning and standardization of New Plants and Equipments Total Quality Management Optimization of resources like manpower, plant and equipments Production Planning and Control ISO 9001 / QS 9000 Quality Management Systems ISO Environmental Management Systems ISO / TS 16949:2002 Quality Management Systems Research and Development Training and Development of personnel Sales and Marketing PROFESSIONAL EXPERIENCE 1. HINDUJA FOUNDRIES LIMITED, CHENNAI June 2001 to Current A. Presently hold responsibility as Divisional Manager-Sales & Marketing August 2007 to Current As the Divisional Manager Sales & Marketing, I am responsible for all the activities of the Department coordinating with the customers and ensuring delivery, quality and cost of the iron and aluminium castings manufactured. This included Production Planning and Control activities also.this also includes outsource activities like Fettling & Machining operations. Also have additional responsibilities of the TQM Activities as outlined below under B. Reports to Plant Director and GM-Commercial B. Held responsibility as Divisional Manager TQM April 2004 to July 2007 Assumes charge as the in charge of the newly created Department Total Quality Management. Responsibilities include Industrial Engineering Department activities As the Management Representative of ISO 9001 / QS 9000 Quality Management System activities As the Management Representative of ISO Environmental Management System activities
2 2 As the Management Representative of ISO / TS Quality Management System activities Institutionalizing the culture of TQM Integrating TQM and Business Process Reengineering Cultural Transformation through Total Quality Managing for Continual Improvement Implementing 5S activities Standardizing Practices, Mapping Processes, Rediscovering the Customers and make quality a strategic planning tool Reports to Managing Director Has successfully completed the Lead Auditor Training course of ISO Quality Management Systems conducted by BVQI, Chennai in October 2004 Has successfully completed the Lead Auditor Training course of ISO Environmental Management Systems conducted by BVQI, Chennai in April 2005 As the Management Representative of ISO Environmental Management Systems, contributed for the certification of Ennore Foundries Limited, Chennai in March 2005 Also assists the Managing Director in all his functions C. Held responsibility as Manager Quality June 2003 to March 2004 As the in charge of Quality Control and Quality Assurance activities both at in-house and at customer ends of the grey iron castings produced catering to the need of automobile, tractor and other engineering industry As the in charge of Chemical and Physical Laboratories As the in charge of Research and Development Department As the Management Representative of ISO 9001 / QS 9000 Quality Management Systems Ensured rejections of castings both at Foundry stage and at Customer ends within the targeted levels Standardized New Products Established and maintained Quality Management Systems to comply with ISO 9001 / QS 9000 Standards Established material standards of the incoming raw materials Developed and established methods and standards in manufacturing D. Manager Sales & Marketing September 2002 to May 2003 As the Manager Sales & Marketing, I was responsible for all the activities of the Department co-ordinating with the customers and ensuring delivery, quality and cost of the iron and aluminium castings manufactured. This included Production Planning and Control activities also. E. Manager Iron Foundry Plant II June 2001 to August 2002 As the Manager Iron Foundry Plant II responsible for Core Shop, Sand System Department, Moulding Shop and Melting Shop in ensuring
3 3 Production Quality Developmental activities Cost reduction Safety of men and equipments etc. 2. ASHOK IRON WORKS LIMITED, BELGAUM, November 1999 to May 2001 KARNATAKA STATE As the General Manager Operations As the Profit Centre Head (Unit Head) whose responsibilities included to ensure Manufacturing of grey iron cylinder blocks and heads meant mainly for generator sets, auto and tractor industries Overall Management of the unit producing intricate castings to the tune of 600 M.T. per month Quality As the Management Representative of ISO 9002 Quality Management System activities 3. LAKSHMI MACHINE WORKS LIMITED - July 1994 to October 1999 FOUNDRY DIVISION, COIMBATORE, TAMIL NADU This most modern world-class foundry was commissioned in July 1994 to produce Grey Iron and S.G. Iron castings with an installed capacity of 1000 M.T. per month. The Foundry is intended to produce automotive cylinder blocks, cylinder heads, power transmission components and allied items contributing for the major production share along with the LMW group s captive requirements of Machine Tool castings and Textile Machinery castings. As the Manager Production Responsibilities included Standardization of processes and equipments in all the Departments. Some of the equipments are Fast Loop Line Moulding line rated at moulds per hour with flaskless moulds with no-bake process, 25 M.T. per hour continuous mixer, etc., where kgs. Castings are produced Heavy Moulding Section Moulding line using moulding boxes with no-bake process, 25 M.T. per hour continuous mixer, etc., where castings weighing up to 5 M.T. are produced Sand Reclamation Plant rated at 15 M.T. per hour Sand Plant with 6 M.T. per hour Core Shop with a) No-bake process with 2 nos. of 6M.T. per hour continuous mixers b) Shell Core Shooters c) Cold Box Core Shooters, etc.,. Melting Shop equipped with 3 nos. of 2.5 M.T. medium frequency induction furnaces, 1 no. of 7.5 M.T. mains frequency induction furnace Fettling Shop Quality Control and Quality Assurance
4 Production Planning Control Sub Contract activities Manpower Planning Co-ordinating with other Departments and other Units of LMW for smooth functioning of the Foundry As Factory Manager As Management Representative of ISO 9002 Quality Management System activities Has completed ISO 9000 Assessor / Lead Assessor course in June ENNORE FOUNDRIES LIMITED, CHENNAI November 1993 to June 1994 A. As the Department Head of Moulding Shop of Plant I in the cadre of Deputy Manager Responsibilities were Production of moulds in high pressure automatic Shoot Squeeze moulding plant rated at 120 moulds per hour using green sand Production of moulds in conventional moulding line at the rate of 40 moulds per hour using green sand Production of heavy castings with pep set process of mould and core making Overall management of the Departmental activities B. As the Department Head of Sand System Department of Plant I in the cadre of Deputy Manager Responsibilities were Production and quality of green sand system with mechanized sand plants for High Pressure automatic Shoot Squeeze Moulding Plant rated at 120 moulds per hour Conventional Moulding line rated at 40 moulds per hour Second Conventional Moulding line rated at 100 moulds per hour Production and quality of core sand system which includes oil sand process, CO2 process, hot box process, shell process and pep set process of core making Production of shell coated sand in the shell coating plant C. As the Department Head of Research and Development June 1990 to October 1993 Department in the cadre of Assistant Manager / Deputy Manager Research and Development Department comprises three wings namely, Process development, Material Development and Equipment Development. Some of the projects for which I was responsible were Sand reclamation Development of Channel Induction Furnace lining material Development of alternate sources of sand Development of ceramic coating for worn out core boxes, dies and patterns In-house manufacturing of hot box catalyst Study on high speed continuous mixers for chemically bonded sand Cost reduction 4
5 5 Development of in-house precoated sand for shell process Standardization of pep set process Development of mould/ core coating materials Development of evaporative mould coating technique for green sand moulds Development of hot melt adhesive for mechanized core assembly Development of system sand for Shoot-Squeeze High Pressure Automatic Moulding Plant rated at 120 moulds per hour Development of core shooters and other equipments Reduction of arc furnace electrodes and power consumption Had undergone training in TEKSID Foundry, Italy for a month in the year 1990 for the development of cylinder block and cylinder head castings. This Foundry produces castings to the tune of M.T. per day D. As the Department Head of both Melting & November 1983 to May 1990 Moulding Shops including decoring plant in Plant II in the cadres of Assistant Superintendent / Superintendent / Assistant Manager Overall responsibilities of the Department which included commissioning and standardization of the New Plant and equipments in the expansion which include 15/20 M.T. Channel Induction Furnace 2 Nos. 10/14 M.T. Arc Furnace 1 No. 5 M.T. / Hour Divided Blast Cupolas 2 Nos. 3.5 M.T. Medium frequency coreless Induction Furnaces 2 Nos. Automatic High Pressure Moulding Plant rated at 40 moulds per hour Decoring plant In a very short period of about one and half years all the plant and equipments were standardized to achieve production in the moulding plant at the rate of 40 moulds per hour Quality of the grey iron castings manufactured were established Systems were developed and established Many newly appointed personnel were trained to attain competency in work Remelting of 20 M.T. of solidified metal in a Channel Induction Furnace at Ennore Foundries Limited, Madras during the cyclone period in November 1984 E. As the Assistant Superintendent in the Projects Department May 1982 to October 1983 for the erection and commissioning of Melting & Moulding Shops equipments in the New Foundry (Plant II) with Gustav Zimmermann Automatic High Pressure Moulding Plant Responsibilities included Erection of Gustav Zimmermann Automatic High Pressure Moulding Plant at the rate of 40 moulds per hour Erection of Melting Shop equipments Erection of decoring plant
6 6 F. As the Shift in - Charge of Melting Shop of Plant I April 1978 to April 1982 in the cadre of Executive Responsibilities were Ensuring production Ensuring quality Manpower optimization Co-ordinating with other Departments for smooth functioning of Melting Shop Standardization of Cupolas Oxygen enrichments of Cupolas Commissioning of 4/5 M.T. Arc Furnace Commissioning of 5 M.T. Mains frequency Induction Furnace Erection and Commissioning of 6/10M.T. Channel Induction Furnace Development of S.G.Iron Optimizing the efficiency of Melting Shop and its operations Cost reduction Standardization of metallurgical quality of castings G. As the Executive Trainee April 1977 to March 1978 Responsibilities were to ensure metallurgical quality of grey iron castings co-ordinating with Customers, Melting Shop, Laboratories, etc. 5. SAMCO METALS AND ALLOYS PRIVATE LIMITED, December 1976 to March 1977 VELLORE, TAMIL NADU As a Management Trainee 6. CENTRAL POLYTECHNIC, MADRAS September 1976 to November 1976 As an Associate Lecturer in the Department of Metallurgy EDUCATIONAL QUALIFICATIONS Completed M.Tech. in 1975 at the Indian Institute of Technology (IIT), Bombay, which is a two year post graduate course, comprising one year course work and one year project work titled Recommissioning of Universal Laboratory Arc Furnace and studies on Chromium Copper Completed Undergraduate Engineering course in the field of Metallurgy in 1973 at the Regional Engineering College, Tiruchirappalli, Tamil Nadu affiliated to University of Madras Completed One year Pre University Course with Maths, Physics and Chemistry in 1968 from St. Joseph s College, Thiruchirappalli, Tamil Nadu affiliated to University of Madras Completed schooling in 1967
7 AFFILIATIONS 7 Was an active Council Member of The Institute of Indian Foundrymen (IIF), Coimbatore Is an active Council Member of The Institute of Indian Foundrymen (IIF), Southern Region for the last 9 years Was a member of The Indian Institute of Metals Was a member of the Collaborative Research Project Associate Group in the field of Metal casting and Technology of British Cast Iron Research Association (BCIRA), U.K. during the career in Ennore Foundries Limited, Madras from Is an empanelled auditor for ISO 9001:2000 QMS & ISO 14001:2004 EMS registered with Bureau Veritas Certification India (BVCI) Ltd. and Indian Register Quality Systems (IRQS) DATE OF BIRTH REFERENCES Addresses Phone Nos. 1. Mr. K. SHANMUGAM Res KS Consultants 934, 6 th Avenue Anna Nagar (West) Chennai India (Ex General Manager of Ennore Foundries Limited, Chennai ) 2. Mr. M.P. PONNUSWAMY Res No. 9 Nagammai Street Raja Annamalaipuram Chennai India (Ex Divisional Manager of Ennore Foundries Limited, Chennai ) 3. Mr. N. RAMACHANDRA Res SREYES 231, Shardha Colony Bhaswesaranagar Bangalore India (Ex Technical Director of Lakshmi Machine Works Limited, Coimbatore )
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