BHARATHIVELU G

Results-driven production professional prepared for demanding roles in manufacturing and operations management. Proven track record of enhancing production efficiency and maintaining high-quality standards. Focused on team collaboration and adaptability to changing project needs, with strong skills in process optimization and leadership.

Six Sigma - Green Belt from AIGPE

· Team Member for Improvement of KE in Manual lines from 50% to 60% in 2017

· Project leader for Improvement of KE in Manual lines from 60% to 70% in 2018

· Inter Sector Versatility Improvement from 2% to 40% within Dec 2018 by doing this optimizing 10 Manpower in 2019 onwards.

· Reduction in number of turns in B1 winding for Jumbolino, savings of 5.2L/annum

· Localization of gas nozzles, savings of 7.8L/annum

· Lean flow for natural curing area

· Lean & ergonomic flow for curing & leak test process

· Reduce BHT & AHT deviation

· Reduce inventory in shop floor location

· Winding speed improvement to improve OEE

· Layout modification in winding for flexible operation & reduced 1 manpower in each shift

· SMED fixtures to avoid change overtime

· Wet line concept

· Change of timings of master samples testing, before it was start of shift now in break timings

· Included Soken testing in line itself to avoid waiting for parts, before it was a separate station

Special Projects:

· Layout optimization in spraying area, Altering direction of spraying booth - Space savings by 125Sq.Mt

· Modified Zinc wire drum & trolley to avoid ergonomic issue

· Improvement of production output from 1600 capacitors per day to 1900 capacitors per day against the target of 2000.

· Reducing sound level & dust level in spraying area

· Implemented Bins for smaller diameter capacitors instead of Trolleys to avoid thread damage & modified trolley for capacity enhancement

• Implemented new Automatic Test Equipment for Single and Three Phase EMI Filters, enhancing testing accuracy and reducing cycle time.
• Deployed a Resin Filling Machine with HMI configuration, improving process consistency and control.
• Installed a Programmable Reactor Winding Machine, enabling in-house production and eliminating outsourcing.
• Introduced a Toroidal Coil Winding Machine to reduce manual operations and boost production efficiency.
• Led Kaizen initiatives to eliminate non-value-added activities, standardize processes with schematic diagrams, and significantly reduce rework and assembly errors.
• Redesigned shopfloor layout using lean principles to align with process flow, resulting in improved operational efficiency.
• Achieved 98% On-Time Delivery (OTD) consistently for 9 consecutive months through strategic planning and execution.
• Improved process reliability and quality by implementing pneumatic crimping, reducing manual errors and ensuring consistency.

• New Machine Implementation: Ensured uninterrupted spraying operations during the pandemic by introducing an ARC machine in place of the Flame machine (Oxygen & LPG-based).
• KE Improvement: Contributed as a team member in improving KE from 50% to 60% in manual lines (2017).
• KE Improvement: Successfully led a project to enhance KE in manual lines from 60% to 70% (2018).
• Multiskilling & Versatility: Improved inter-sector versatility from 2% to 40% by optimizing manpower; 10 resources redeployed effectively from 2019 onwards.
• Cost Saving: Reduced turns in B1 winding for Jumbolino, achieving annual savings of ₹5.2 Lakhs.
• Cost Saving: Localized gas nozzles, resulting in annual savings of ₹7.8 Lakhs.
• Process Improvement: Redesigned curing and leak test processes to ensure lean and ergonomic workflow.
• On-Time Delivery & Customer Satisfaction: Reduced BHT and AHT deviation, improving customer satisfaction.
• Inventory Management: Minimized shopfloor inventory by implementing lean stock practices.
• Productivity: Increased winding speed, leading to significant improvement in Overall Equipment Effectiveness (OEE).
• Lean Flow & Manpower Optimization: Modified winding layout to enable flexible operations, reducing 1 operator per shift.
• Changeover Efficiency: Applied SMED fixtures and introduced Wet Line concept to minimize changeover time.
• Productivity: Rescheduled master sample testing from shift start to break time, avoiding production interruption.
• Lean Flow: Integrated Soken testing into the main line, eliminating waiting time at a separate testing station.
• Space Optimization & Lean Flow: Altered the spraying booth direction, achieving 1200 sq. ft. of space savings.
• Ergonomic Improvement: Modified zinc wire drum and trolley design to resolve ergonomic issues.
• Productivity: Boosted production output from 1600 to 1900 capacitors/day, nearing the 2000/day target.
• Workplace Environment: Reduced noise and dust levels in the spraying area, enhancing operator safety and comfort.
• Customer Satisfaction & MDR Reduction: Introduced bins for smaller-diameter capacitors to prevent thread damage and redesigned trolleys to increase capacity.