Kulasekar Sethupathy
Alpharetta,GA
Overview
29
29
years of professional experience
Work History
Solution Specialist Leader - Lean
Barry Wehmiller Design Group
Atlanta, GA
04.2014 - Current
- Serving as a leader of an internal consulting group capable of Assessing client manufacturing processes, designing and facilitating Lean solutions for the organization's greatest needs.
- Being as a subject matter expert (SME) for lean manufacturing projects for discreet and continuous manufacturing domain.
- Guide the strategic direction of the group as well as identify and prioritize high-impact projects for the entire enterprise's performance.
- Experience in developing a “state of the art” technology road map that enables customer’s mission, vision, and future leadership.
- Developing current and future state Value stream mapping (CSM/VSM) for the complete factory process and identify areas of improvement to reduce the NVA activities.
- Strategize to understand the inventory flow, manufacturing flow and process triggers and come up with equipment lay-out by calculating the most efficient use of plant square footage.
- Our team handles projects such as the evaluation and improvement of key work processes, development and implementation of tools designed to enhance enterprise productivity, and providing operational support to the design and roll-out of key technology initiatives.
- Streamlined operational processes and collaborated with management to implement process improvements.
- Primary point of contact with clients for the Lean projects I manage and work closely with other SME's such as Warehouse Solutions, facility solutions in the organization to provide an overall solution/roadmap.
- Conduct Root Cause analysis on implemented recommendations - identify areas of success and identify any further analysis or improvements needed.
- Resolved customer issues quickly and efficiently to enhance overall customer satisfaction ratings.
- Implemented corrective actions to fix root causes of various issues.
- Worked on optimized production strategy, material handling design, flow statistics & comparisons, staging & inventory, DFMEA, line stoppage scenarios, quality flow requirements, functional specification for the line.
- Using simulation resources, simulated the line and identified the areas for improvement, analyzed the line behavior and addressed the need for CAPEX investment and line optimization.
Delivery Manager-Lean
Barry Wehmiller International
Atlanta, GA
06.2011 - 10.2012
- Manage project delivery team, administrate projects, and provide execution strategies for the team to meet on time delivery, cost and quality standard to achieve the business goals.
- Direct and steer customer engagements, lead project delivery team effectively and ensure the projects are handed over successfully per Client expectations.
- Responsible for engineering design project initiation, planning, execution, monitoring & control to closure of project as per PMI standards.
- Measure project performance using MPP, Perform risk management to minimize project risks track and communicate project status to all stakeholders and create and maintain comprehensive project documentation.
- Implemented Lean Principles such as 5S, Standard Work, Kanban, Value Stream Management, Takt and Cycle Time Calculation, Balancing Operator Loading, Poka-Yokes, Material Pull Systems, Visual Management, Transactional Process Improvement, Variation Reduction and Total Productive Maintenance at client sites.
- Developed and measured Key Performance Indicators for various departments and held them accountable for performance improvement for the client projects.
- Trained and facilitated kaizen teams that realized over $1 million in savings and revenue generation.
- Consulted and trained departments and senior leadership regarding process improvements, performance measures, waste and variation reduction, and structured problem solving.
Project Manager
Barry Wehmiller International
Atlanta, GA
04.2008 - 10.2013
- Led and managed the Manufacturing Practice with 6 member team
- Accountability for revenue of $ 1 million with a team size of 4 people; direct managerial responsibility for 5 projects at a time.
- RFQ to Proposal by solution architecting to US and Europe customers for manufacturing requirements.
- Visiting customer sites in USA, Europe, China, and Malaysia to conduct assessments from the Lean perspective and providing solutions to improve the line efficiency.
- Planned, designed, and scheduled phases for large projects. Managed projects from procurement to commission.
- Developed Project management process @ BWIR – Manufacturing group as per PMI standards in Hoshin Kanri process.
- Being as a project manager, experienced in project initiation, planning, execution, monitoring & control to closure of engineering design/ automation project as per PMI standards.
- Measure project performance using MPP, track and communicate project status to all stake holders through weekly reports and present quarterly progress through power point presentations.
- Develop project scopes and objectives, involving all relevant stakeholders and ensure technical feasibility. Ensure resource availability and allocation and develop a detailed project plan to track progress.
- Conference calls with customer to review the project status and its goals to manage progress and demonstrate the commitment towards project metrics.
- Experienced in coordinating, negotiating and motivating outside vendors and evaluate and secure vendor contracts for manufacturing projects and develop solid relationships with the vendors.
- Coordinate internal resources and third parties/vendors for the flawless execution of projects. ensure that all projects are delivered on-time, within scope and within budget
- Perform risk management to minimize project risks and create and maintain comprehensive project documentation.
Deputy Manager - Manufacturing Engineering
Rane Madras
Chennai, India
04.2006 - 05.2008
- Led 4 member team of Manufacturing Engineers and handled the Steering Gear and Suspension linkage product manufacturing and assembly process.
- Supported Manufacturing Engineering Activities such as Productivity improvement, Process Robustness and New Production development and implementation for the above products.
- Experience in forming Lean cells, conduct value stream mapping of product, developing line layouts, and balancing lines.
- Successful integration of online packing with the assembly cell for the suspension linkage products
- Worked with Japanese TQM Consultants(Yushida San) to implement the TQM process and helped the organization to win Deming Prize.
- Experience in conducting process audits in the manufacturing process and identify and implement improvements
- Experience in Productivity improvements, Ergonomic factor of view projects by motion study, Space utilization & reduced travel distance.
- Implemented VA/VE activities results 20% material & cost saving in top 3 parts Standardization of systems and documents for sustenance of improvements
- Implemented 43 Mistake proofing during new product development stage & Customer complaint
Manager - TPM
IM Gears Ltd
Chennai, India
05.2001 - 04.2006
- This role is to support the organization's TPM implementation program, communicating with everyone and leading by example to develop the standards, skills and delivery materials required to achieve the organizational objectives through sustainable improvements.
- Organization wide TPM Coordinator to implement 8 pillar approach.
- Conduct 5 s audits across the organization, share ideas to improve, implement the improvement projects using the team and rated as one of the high 5s score maintained organization in the state.
- Experience in implementing all 8 Pillar approach such as Autonomous Maintenance,
- Partnering with employees in all TPM areas to drive engagement, understanding, and expansion
- Drive focused improvement in downtime/slowtime, quality, productivity and reduction of costs during the Journey to JIPM Certification
- TPM Pillar execution - Measured improvement through TPM Audit/Assessment Scores
- Train, coach, and develop all levels of leadership and teams on TPM
- Develop standard operating procedures, standard work, OPLs, and other tools
- Coach employees on the OPL process, including how to complete one, and assist in the ongoing tracking and maintenance of the OPLs for document control
- Coach and champion employees on 5S initiatives
- Educate and coach the team on how to effectively execute lean processes and techniques
- Engage employees in incorporating TPM tools and processes into their areas of responsibility
- Attend all TPM meetings, working with leaders to advance team capabilities in problem solving, critical thinking, and analysis of issues to root cause solutions
- Facilitate problem solving methods and Cost reduction projects Energy saving, Ergonomics, SMED, VA/VE, Cycle time reduction, and safety.
Engineer - Quality Assurance
Accurate Forge & EL Forge Ltd
Chennai, India
04.1994 - 04.2001
- Practiced ISO/TS 16949, ISO 14001 & TQM systems
- Knowledge in preparation of FMEA, PFD, CP & SOP.
- Conducting process audit in the line by 6 M methodology.
- Poka yoke for Customer complaints & identification of scope for process variation.
- Assessed investigation reports of subordinate quality assurance personnel and addressed any procedural deviations.
- Monitored testing processes, test development and user acceptance testing.
Education
Bachelor of Science - Engineering Technology
BITS-Pilani
India05.2012
Six Sigma
Indian Statistical Institute -Chennai
India03.2011
Lean Machine System
The Associate For Overseas Technical Scholarship
Japan03.2004
Associate of Applied Science - Diploma in Mechanical Engineering
Department of Technical Education
India05.1994
Skills
- LEAN practitioner
- Project management
- Solutioning /Problem Solving
- TPM/TQM Implementation
- Workflow planning
- Risk Management
- Six Sigma -DMAIC
- Quality Management Systems
- Machine Design/Automation
- Team Development
Accomplishments
An experienced, disciplined, and highly motivated Operational Excellence Leader with extensive knowledge in using Lean best practices across the organization, ability to conduct value stream mapping sessions, develop current and future state processes, manufacturing strategies, waste elimination, solution development that meet goals and budget.
Timeline
Solution Specialist Leader - Lean
Barry Wehmiller Design Group
04.2014 - Current
Delivery Manager-Lean
Barry Wehmiller International
06.2011 - 10.2012
Project Manager
Barry Wehmiller International
04.2008 - 10.2013
Deputy Manager - Manufacturing Engineering
Rane Madras
04.2006 - 05.2008
Manager - TPM
IM Gears Ltd
05.2001 - 04.2006
Engineer - Quality Assurance
Accurate Forge & EL Forge Ltd
04.1994 - 04.2001
Bachelor of Science - Engineering Technology
BITS-Pilani
Six Sigma
Indian Statistical Institute -Chennai
Lean Machine System
The Associate For Overseas Technical Scholarship
Associate of Applied Science - Diploma in Mechanical Engineering
Department of Technical Education
Similar Profiles
Thomas QuinnThomas Quinn
Project Engineer at Barry-Wehmiller Design GroupProject Engineer at Barry-Wehmiller Design Group
McKenna SnyderMcKenna Snyder
Project Accountant at Barry Wehmiller Design GroupProject Accountant at Barry Wehmiller Design Group
Erika ArmstrongErika Armstrong
Administrative Assistant at Barry Wehmiller Design GroupAdministrative Assistant at Barry Wehmiller Design Group
Kysa ScottKysa Scott
Senior Underwriter at N2G Worldwide Insurance Services, LLCSenior Underwriter at N2G Worldwide Insurance Services, LLC
Jimmy MauldinJimmy Mauldin
Deputy Chief of Mission at U.S. Embassy, Department Of StateDeputy Chief of Mission at U.S. Embassy, Department Of State