Jay Kuruvilla
Dover
Summary
Results-driven operations leader with extensive experience in aerospace manufacturing, facility management, and operational excellence. Demonstrated expertise in leading cross-functional teams, implementing lean principles, and managing large-scale projects to achieve cost efficiency, productivity, and quality goals. Skilled at fostering innovation, ensuring regulatory compliance, and delivering superior products in fast-paced environments. Committed to aligning operations with strategic business objectives to drive organizational success.
Overview
7
7
years of professional experience
Work History
Manufacturing Manager
Howmet Aerospace
10.2023 - Current
- Develop and Lead High-Performing Teams: Mentor and coach a team of 300+ employees, fostering professional growth and succession planning to strengthen organizational capabilities.
- Drive Business Growth: Spearheaded initiatives to grow the business from $200M to $250M through operational efficiency, strategic investments, and enhanced customer engagement.
- Strategic Vision Execution: Develop and execute a comprehensive five-year strategic plan targeting $500M in revenue by aligning operations with business goals, optimizing resources, and pursuing market opportunities.
- CapEx Planning: Lead capital expenditure projects to support strategic growth, including equipment upgrades and infrastructure improvements to enhance capacity and productivity.
- Operational Efficiency: Implement lean manufacturing principles and continuous improvement strategies to reduce waste, optimize processes, and improve cost-effectiveness across the facility.
- Safety and Compliance Leadership: Prioritize a zero-accident safety culture by implementing rigorous protocols, conducting audits, and ensuring regulatory compliance.
- Data-Driven Decision Making: Utilize key performance indicators (KPIs) and financial metrics to monitor progress, evaluate performance, and inform strategic decisions.
Front End Operations Manager
PCC - McWilliams Forge Co
12.2022 - 10.2023
- Manage $6M Critical Asset Rebuild Project
- Manage front end operations P&L to TOC Metrics / budget, effectively allocating resources to maximize operational efficiency & achieve cost targets
- Lead continuous improvement initiatives, fostering a culture of innovation & encouraging employees to suggest process enhancements for ongoing success
- Conduct performance evaluations & implement training programs to enhance workforce productivity / proficiency
- Develop & implement contingency plans to mitigate risks & ensure uninterrupted operations during unexpected events or crises
- Collaborated with cross-functional teams, including engineering/design, sales, operations, and EHS to ensure seamless implementation of safety protocols, regulatory guidelines, and costs
- Implemented risk protocols & countermeasures, driving efforts to drive towards a zero-accident record, prioritizing employee well-being & regulatory compliance
- Collaborated with procurement customers to manage inventory levels & meet production deadlines, maintaining strong relationships & identifying new growth opportunities
- Oversee maintenance & upkeep of forging equipment, minimizing downtime & extending the lifespan of critical machinery
Manufacturing Engineer
PCC - McWilliams Forge Co
01.2022 - 12.2022
- Plan and execute multimillion dollar capital improvement projects (Machinery, Building improvements, etc.)
- Identify and improve any manufacturing issues (Machine & Process related)
- Develop and implement new manufacturing solutions for various non conformances Create
Forge Supervisor - Management Development Rotation
PCC - McWilliams Forge Co
07.2021 - 12.2021
- Achieved daily throughput goal for forge operations
- Planned and submitted Capital Acquisition Requests (CAR) for preventative maintenance, equipment for strategic growth, and facility renovations.
Forge Process Engineer - Management Development Rotation
PCC - McWilliams Forge Co
01.2021 - 07.2021
- Conducted zero defects project resulting in approval to ship $110K of product and Excess & Obsolete Reduction of $120K
- Implemented the use of IR cameras to reduce variable cost (VC) and improve productivity
- Saw Shed Productivity & Capacity Improvement
- Productivity increase of 41% within the area and 2.5% plant-wide downtime
- VC/ESH reduction of $6.60 in the area and $3.04 plant-wide
- Increased ESH By 40% with same labor inputs
- Assisted Quality Manager with customer audits
Heat Treat & NDT Supervisor - Management Development Rotation
PCC Fasteners - SPS Technologies
07.2020 - 12.2020
- Managed 24/7 production of nut, bolt, and flexloc product lines through two major batch departments
- Fulfilled TOC and Flex responsibilities for both product lines at $1.8M of combined daily throughput
Project Manager, Adv Manufacturing - Management Development Rotation
PCC Fastener Division
01.2020 - 07.2020
- Managed long-term projects to offload up to 10% of SPS Jenkintown's workload to Low-Cost Country facilities such as Metalac in Brazil
- Project Manager for14.7M CAR for the Fasteners Division Titanium Pin Center of Excellence with coordination with division finance, Air Industries Product Engineers, TJ Brooks Product Engineers, and multiple machine vendors – both domestic and International
- Developed Safety Program for Ti Pin CoE's pilot site. This includes contractor safety policy, LO/TO program, hot work program, etc
Supplier Quality Engineer - Co-Op
PCC Aerostructures - Walden's Machine
03.2019 - 12.2019
- Interpreted engineering drawings & 3D Cad models
- Reviewed/submitted First Article Inspection Reports to customers
- Dispositioned Material Rejection Reports (MRR’s)
- Processed Vendor Return Merchandise Authorizations (VRMA’s)
- Prepared Customer Corrective Actions
Quality Engineer - Co-Op
PCC Aerostructures - Walden's Machine
08.2018 - 03.2019
- Developed quality inspection plans in compliance with customer engineering requirements
- Analyzed Manufacturing Plans & Engineering Changes for accuracy to the engineering data
- Reviewed Specifications to ensure parts were being manufactured according to the specifications
- Reviewed and submitted First Article Inspection Reports to customers
- Provided Materials Review Board support, dispositions for product nonconformance to restore the aircraft structure to meet the intent of the certified design, coordinate activities between production, engineering, manufacturing
Continuous Improvement Engineer - Intern/Co-Op PCC
Aerostructures - Primus International
01.2018 - 07.2018
- Applied principles of lean manufacturing / Kaizen / Six Sigma to optimize productivity
- General Assembly cell optimization / creation
- Prepared & documented technical engineering procedures and provided training to operators
- Completed corrective/preventative action report for root cause analysis
Education
B.S. - Mechanical/Aerospace Engineering
Oklahoma State University
Skills
- Lean 6 Sigma
- Project Management
- Team building and development
- Written & Verbal Communication
- Technical Problem Solving
- ERP Systems
- Continuous improvement & 6S
- Forecasting
- Operations management
Timeline
Manufacturing Manager
Howmet Aerospace
10.2023 - Current
Front End Operations Manager
PCC - McWilliams Forge Co
12.2022 - 10.2023
Manufacturing Engineer
PCC - McWilliams Forge Co
01.2022 - 12.2022
Forge Supervisor - Management Development Rotation
PCC - McWilliams Forge Co
07.2021 - 12.2021
Forge Process Engineer - Management Development Rotation
PCC - McWilliams Forge Co
01.2021 - 07.2021
Heat Treat & NDT Supervisor - Management Development Rotation
PCC Fasteners - SPS Technologies
07.2020 - 12.2020
Project Manager, Adv Manufacturing - Management Development Rotation
PCC Fastener Division
01.2020 - 07.2020
Supplier Quality Engineer - Co-Op
PCC Aerostructures - Walden's Machine
03.2019 - 12.2019
Quality Engineer - Co-Op
PCC Aerostructures - Walden's Machine
08.2018 - 03.2019
Continuous Improvement Engineer - Intern/Co-Op PCC
Aerostructures - Primus International
01.2018 - 07.2018
B.S. - Mechanical/Aerospace Engineering
Oklahoma State University
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