JAYAPRAKASH VISWANATHAN
Chennai
Summary
Proven Production Leader with 19+ years in two-wheeler OEM manufacturing, specializing in motorcycle & scooter assembly line excellence. Expert in Lean, Kaizen, TPM, Poka-Yoke, and Zero-Defect processes, with a strong record of cutting cycle times, scaling capacity, driving flawless new model launches and man power optimization. Recognized for optimizing takt time, ensuring OEM compliance, and building high-performance teams to deliver world-class quality and efficiency.
Overview
19
19
years of professional experience
1
1
Certification
Work History
Operation & Business Development Manager
Chasmal Services Pvt. Ltd.
Chennai
08.2024 - Current
- Oversee daily operations of the laundry facility ensuring timely and quality service delivery.
- Manage workforce scheduling, performance, and training to maximize productivity and customer satisfaction.
- Monitor inventory and procurement of detergents, chemicals, and machine spare parts.
- Ensure adherence to safety, hygiene, and environmental standards across all service areas.
- Analyse operational reports and KPIs to identify bottlenecks and develop corrective actions.
- Identify new business opportunities and potential clients to expand the customer base.
- Develop and maintain strong relationships with corporate clients and institutional partners.
- Coordinate marketing initiatives, including promotions, customer outreach, and digital presence.
- Conduct market research to understand competitor offerings and customer expectations.
- Prepare business proposals, service presentations, and pricing models tailored to client needs.
- Track sales performance, customer feedback, and develop improvement plans accordingly.
Assistant Production Manager
India Yamaha Motors Pvt. Ltd.
Chennai
09.2017 - 08.2024
- Execute and monitor daily production schedules, takt time, and cycle time adherence.
- Ensure FIFO (First In, First Out) discipline for component feeding and WIP management.
- Coordinate manpower allocation and workflow with supervisors and operators.
- Drive Zero Defect Process Implementation (ZDPI) across assembly stages.
- Deploy Poka-Yoke (mistake-proofing devices) to eliminate defects and improve first-pass yield.
- Enforce Hyoujun Soubi (Standard Assembly Practices) for critical fitments.
- Conduct structured root cause analysis (5-Why, Fishbone, Pareto) and implement corrective/preventive actions.
- Lead Kaizen initiatives to reduce cycle time, cost, and waste while improving ergonomics and efficiency.
- Implement 5S workplace discipline and apply 6F (Safety, Quality, Cost, Delivery, Morale, Environment) monitoring.
- Drive TEI (Total Employee Involvement) and QCC (Quality Control Circle) for shop floor improvements.
- Support SMED, TPM, and lean manufacturing projects to improve OEE and productivity.
- Work with CFT (Cross Functional Teams) for trial runs, process validation, and issue resolution.
- Support New Product Development (NPD) production trials, including fixture validation, assembly sequencing, and line readiness.
- Provide feedback for manufacturability, ergonomics, and tooling during proto builds.
- Ensure preventive & corrective maintenance of jigs and fixtures to maintain accuracy and repeatability.
- Oversee pneumatic tool preventive maintenance for torque accuracy, safety, and tool-life management.
- Coordinate calibration and tool servicing with maintenance teams.
- Ensure uninterrupted component availability via Kanban/pull system.
- Collaborate with PPC, logistics, and stores to prevent shortages and line stoppages.
- Troubleshoot assembly-related issues in engine fitment, chassis, electrical, body, and testing stages.
- Conduct line audits for safety and enforce PPE compliance.
- Support structured PDCA/DMAIC problem-solving approach for recurring issues.
Senior Executive - Quality Engineering & Control
TVS Motor Company
Hosur
12.2013 - 06.2017
- Conducting Sunrise & Sunset meeting along with Quality Team leader’s & Line Quality inspector’s
- Updating & monitoring daily Engine rework
- Conducting Hourly PDCA along with Production Group leader
- Conducting Engine rework/scrap meeting along with Production, Machine shop, Gear shop & Supplier quality team to eliminate it
- Daily audit of Product, process, Poka yoke, torque, critical
- Identify & taking critical projects to reduce engine rework PPM
- Verification of Machine fixtures which is controlling Product parameter
- Controlling Leak, Side, Test bed & Vehicle return related Engine defects
- Verification of Engine oil contamination
- Conducting Experimental Job Order for new product & new process
- Supporting to NPD DFMEA & Approval of Engine assembly PPAP
- Problem solving through TPM Figure 8 concept
- Visiting Dealers & Customers in order to improve the voice of customer & to improve
Engineer - Quality Assurance
Rane Engine Valves Ltd.
Trichy
09.2011 - 12.2013
- Monitor and audit production processes at each stage (e.g., welding, painting, engine assembly).
- Ensure adherence to Standard Operating Procedures (SOPs) control plans.
- Identify process deviations & implement corrective actions to prevent recurrence.
- Analyse defects found during in-line inspections or final audits.
- Root cause analyse using 7QC tools for defect preventions & Field failures.
- Collaborate with MFG & R&D teams to implement permanent solutions.
- Prepare 8D or CAPA reports and ensure timely closure of customer issues.
- Maintain records of inspection results, audit findings & corrective actions.
- Prepare daily/weekly quality dashboards and share with cross-functional teams.
- Provide feedback to design & manufacturing teams based on customer insights.
Engineer - Quality Assurance
Gabriel India Ltd.
Hosur
05.2006 - 09.2011
- Conduct Inprocess audit, Product audit, Poka yoke audit in Daily basis
- Identify process deviations & implement corrective actions to prevent recurrence.
- Analyse defects found during in-line inspections or final audits.
- Root cause analyse using 7QC tools for defect preventions & Field failures.
- Visit customer end and identify the defects
- Maintain records of inspection results, audit findings & corrective actions.
Education
BIE - Production Management & Human resources Management
DEEE - undefined
Skills
- Production Management
- Quality control & Assurance
- Safety Compliance
- Lean, 5S,6F, Kaizen, TPM & TQM
- Assembly Process Planning
- Equipment Management
- Production scheduling
- Budgeting & Cost Control
- Project Management
- Problem-solving
- Cross-Functional collaboration
- Process Improvement
- Data analysis
- Reporting and Documentation
- Communication & Time Management
- Training & Development
- Attention to detail & Resilience
Accomplishments
- Standardization of all process and smooth flow establishment for 1000veh/shift of Scooter & Motorcycle in IYM
- Hyujoun Soubu activities implemented in AEROX line in IYM
- Man power optimized and process efficiency improved in 06M Scooter line sub assembly group 5 thru TVP approach in IYM
- Achieved 2000 PPM in Scooter Engine at TVSM
- Eliminated Cover oil pump leak rework in Scooter Engine at TVSM
- Best performance award from India Yamaha Motor Limited for achieving 230ppm as against the target of 500ppm for the of year April 2010 in M/s Gabriel
Affiliations
- Member – Indian Institute of Industrial Engineering (IIIE)
- Active participant in OEM-driven Quality Circles (QCC) and Cross-Functional Teams (CFT)
- Contributor to Total Employee Involvement (TEI) programs in two-wheeler manufacturing
- Participant in Kaizen & TPM Excellence Awards organized by OEMs and industry bodies
- Associated with Lean Manufacturing Competitiveness Scheme (LMCS) under MSME
Certification
- SIX SIGMA BLACK BELT - Benchmark
- Awareness of TQM, ISO/TS 16949, PPAP, APQP, ISO 14000, Kaizen and JIT, TPM,SPC
- FVPA at TVSM – HOSUR.
Additional Information
Professional Interests
- Lean Manufacturing & Continuous Improvement (Kaizen, TPM, 5S)
- Zero-Defect Manufacturing & Poka-Yoke Innovations
- New Product Development (NPD) & Prototype Trials
- Automotive Technology Trends (EV scooters & motorcycles, automation, Industry 4.0)
- Cross-Functional Team Collaboration (QCC, TEI, CFT initiatives)
- Process Automation, Robotics, and Smart Assembly Systems
- Motorsport & Two-Wheeler Innovations
- Technical Workshops, Industry Seminars, and Plant Visits
- Mentoring and Training Young Engineers
- Fitness & Outdoor Activities (cycling, trekking, running – to show discipline and stamina)
LANGUAGES
English (Fluent)
Tamil (Fluent)
Hindi (Basic)
Telugu (Basic)
Personal information
- Married
- DOB : 1988-03-21
- Blessed with 2 Children
- Hometown is Trichy
- Currently lives in Chennai
Timeline
Operation & Business Development Manager
Chasmal Services Pvt. Ltd.
08.2024 - Current
Assistant Production Manager
India Yamaha Motors Pvt. Ltd.
09.2017 - 08.2024
Senior Executive - Quality Engineering & Control
TVS Motor Company
12.2013 - 06.2017
Engineer - Quality Assurance
Rane Engine Valves Ltd.
09.2011 - 12.2013
Engineer - Quality Assurance
Gabriel India Ltd.
05.2006 - 09.2011