Manjunath Ram

Experience

• 

  Toyota Kirloskar Motor

  Oct 1999 - May 2011

  Since 2008 Asst. Manager  Holds the distinction of leading a team of 107 members. Demonstrated excellence in establishing Quality systems such as Kanban and QC Circle from scratch in Toyota. Played a pivotal role in establishing repair and quality standards for Press Panels in coordination with Japanese Quality Experts. Excellent track record of increasing the Production Line efficiency and productivity by 15% and 20% respectively through effective implementation of Kaizen and Process Study. Instrumental in implementing Best Safety Foolproof System thereby leading to manpower reduction and productivity & workability improvement. Ensured the implementation of in-built quality tools and problem solving methods to achieve DPP. Developed Standard Operating procedures for all machinery and equipment; organised training programs on the same for employees at all levels of the organization. Participated extensively in Inventory Management. Successfully conducted meetings with related departments depending on the nature of problem; generated daily, weekly & monthly Quality Problem reports and Investigation & Counter Measure reports. 60% breakdown reduced by effective TPM points generating. Overall Achieved 13% of rejection by improving DPP.Awards Won Won 1st Place in Plant QCC in 2010 and to be represent in Global QCC Indonesia.(May 2011) Won Excellent Award in NCQC Vishakapatanam 2010 and to be participate in Japan for ICQC. ( Sep 2011 ) QCC Master Trainer;  Won Best Quality Shop in 2009. Show less 2004 – 2008 Group Leader – Press Department Successfully managed complete operations including Production, Quality and Safety for 2 shifts of 18 Hours. Established facilities and plant operations from scratch; developed various systems/procedures thereby leading to cost savings and greater productivity. Holds the distinction of designing, developing and implementing projects related to Automobile Press Parts; worked in continuous interaction with vendors for development of products. Implemented Press Panels repair & quality standards in coordination with Japanese Quality Experts. Workabilty improvement in bottle neck process resulting in SPM and GSPH improve. Auto unloading system effectively implemented for 38 process,for Man power reduction, improve SPM and GSPH New modle Innova Quality Gate concept implementation . Ensured Zero Rank –A defects to following process. 70% Panel rejection achieved by Implementing FAT ( Formability Acessement Test ) system. Show less  Successfully established Production standards by training and implementing in-built quality & problem solving measures in order to achieve targeted DPV. Developed Standard Operating procedures for all machinery and equipment and trained employees at all levels. Played a key role in counseling team members to resolve their grievances and develop mutual trust. Managed various administrative tasks including data collection and preparation of meetings & presentations. Instrumental in maintaining good working environment by implementing 5S concept. Dry light introduction for surface check, resulting in good quality and rejection percentage control Training at AOTS, Japan. Toyota Production System viz. Kanban and Poke Yoke Systems at TMC, Japan.  Checking Fixture Manufacturing and Product Measuring.  Training in TPS,TJI,TCS,PST,STD.WORK,TBP, QCC Master Trainer.( Certified by Japanese Experts ). Toyota CRJ & KIJ Activities and Implementing in the Process. Show less

  • Assistant Manager

    Mar 2007 - May 2011

  • Group Leader

    Mar 2004 - Mar 2007

  • Team Leader

    Oct 1999 - Mar 2004
• 

  SKF Bangalore

  May 2011 - Feb 2012

  Manager -Business Excellence

  • Deployed Business excellence & TPM in assigned factor as well as created Manager’s Model area • Offered support to the Business excellence board in designing TPM program• Worked as Master Facilitator for managers and worker in training various aspects of manufacturing excellence• Designed and coordinated training modules for workers and checked effectiveness of training• Identified quarterly/monthly/weekly/daily action plan for ME deployment; reviewed action plan & ME culture development• Completed the key milestones of BE deployment and ensured that BE scorecard was implemented in the factory• Drove 5s campaign and its deployment in the factory as well as published ME and 5s MIS• Involved in:o TPM pillars meetingso Publishing news items and articles showcasing systematic deployment/successes and returns to the factoryHighlights:• Essayed a key role in organizing 100 % training for: o Associates within 3 months in 2011o All Middle & Top management employees in 2012• Holds the merit of winning 1st place in INSAAN Kaizen Competition National Level at Jamshedpur in 2011• Demonstrated excellence in the establishment of KAIZEN area for continuous improvement to support production • Distinction of representing SKF India Limited in CII, 18th KAIZEN Conference at Delhi in 2012• Successfully attended Global Training Boot camp ( Overseas & Certified Trainer )for 4 weeks• Was Certified Business Excellence Champion by SKF Group• Augmented revenue by 3% and share by 1% through the implementation of BE culture strategies • Developed strategic and operational plans which resulted in 2% increase in overall gross margin• Identified and established successful plans to develop them, thereby bringing in 10 Million worth additional revenue Show less

• 

  SKF INDIA LTD.

  May 2012 - Jun 2016

  Head - Business Excellence for Manufacturing - Global.

  Head- Business Excellence,( Global ) Asia,Europe & Latin America.1. Key Responsibilities. As a International Management Employee (IME) represents SKF group. Playing a mojor role in Cultural change.(In the areas mentioned in below key responsibilities) Member of Change team management SKF group. Part of Stratergy,and decision making on how to move forward with BE.( Recently attended in Paris / Sweden –Jun-12) Deployment Responsible to drive and moniter the status of BE in assigned Business units.2. Job Purpose :To Formulate and implement various Business Excellence initiatives of the organization.1. Plan and develop overall strategy and roadmap for Business Excellence for organization2. Initiate and support implementation of various best in class practices in the organization3. Planning & Implementation of QMS, EMS, H&S related systems & practices4. Guide HODs for implementing system and review progress status with them.5. Plan & conduct QMS, EMS, H&S internal audit.6. Follow up for closing gaps in the system7. Building competency of the personnel on various BE elements8. Liaison with external agencies like certifying bodies, consultants etc.9. Providing facilitation & support to DMRs10. Conducting quality competitions11. Conducting plant MR meetings12. Facilitation for learning & implementation of core tools & techniques13. Conduct training for management staff on BE practices, QMS, tools and techniques14. Guide and implement teams on various core tools & techniques - APQP, PPAP, FMEA, DCP, MSA, SPC15. Guide and implement teams on various Problem Solving methods - QC Story, G8D, 7 QC Tools, DOE, Six Sigma etc.. Show less

• 

  Vestas

  Jun 2016 - Jul 2021

  SPECIALIST OPERATION EXCELLENCE ( Global )

  => LEAN and TPM - SPECIALIST- OPERATION EXCELLENCE.• Operational Excellence core initiate, roll-out and implement in full “Process improvement projects” using Lean thinking and Methodologies / Six Sigma tools for better efficiency & Cost savings across the organization covering all functional areas viz. Technology, Manufacturing, Construction / Installation Sites, Service & other Support functions.• Process Improvement SPECIALIST - Operational Excellence implementing various improvement Lean methodologies & Production Systems across all functional areas of VESTAS world-wide.• Validation / assessment of existing Processes in each functional area and working for improvements in process & thereby in Cost – Spend through selection and scoping of individual relevant projects / Tasks.• Change Management Skills ensuring successful implementation of the changed processes in Various functional areas & also in Various regions across the globe ( i:e ) to train, Coach, Instruct on how to use the new Process / System & Measure results etc…. ( KPI Monitering )• Conduct the workshops & process improvement trainings through Kaizen, VSM, Standard work, 5s, DM, Pull,TPM, QBD and other Lean tools & methods etc….• Identification of the and proactive mitigation of the key risks in functional areas including appropriate communication to local key stake holders and Management team.• Responsible for implementation of the identified or improved processes in respective functional areas of the organizations & also for reporting cost savings achieved through those process improvements with a deep knowledge not only in process improvement tools, But also converting the same into Cost savings at multiple Levels & also in efficient reporting methodologies.• Contribution to further development of a process road map for future as well with a visionary thought and efforts.• Take Responsibility for own area and interact as integrated team member with other team member. Show less

• 

  Vesuvius India & South East Asia

  Aug 2021 - now

  • Associate Director

    Sept 2024 - now

  • Plant Head - Advanced Refractory INDIA

    Aug 2021 - Aug 2024