Curriculum Vitae

Name : KANNAIYAN UDAY KUMAR

Email ID : kannaiyanuday@gmail.com
Mobile No : +91 9000886577/ +91 901077092
Address : H. No. 147B, Nadhinagar, Keesara, Hyderabad - 501301

To work in an esteemed organization where I can prove my process engineering experience and work towards
the growth of the organization.

Total Experience: 5.0 years 10 months (From Aug’10 to till date).

CURRENTLY EMPLOYED:
Tecumseh Products India Pvt.Ltd. Balanagar Township as Assistant Manager in Manufacturing Engineering &
Tool Design

Company Profile: Tecumseh Products is an HVAC compressors manufacturing company in India. Tecumseh is
the only unit in India which manufactures Reciprocating, Rotary compressors & now an AC manufacturing
company as well. Tecumseh is a Global mfg organization which has its branches in Brazil, France, China, India
& U.S which drives all the above units, where as in India there are 2 braches, 1 in Balanagar, Hyderabad &
Other in Ballabgarh, Haryana which manufactures compressors for refrigeration unit. Tecumseh is the only
leading compressor manufacturer in India.

Roles and Responsibilities:

 Tooling and fixture development which enables multitasking abilities

 New product development, product launch, Productionisation and testing
 Responsible for routing maintenance of all product family in Tecumseh Hyderabad and training new
joiners in routing maintenance both in Hyderabad & Ballabgarh (Delhi) plants

 Raising capital expenditure request and seek approvals from management for any new equipment
requirement

 During low production volumes implement lean principles by doing current and future state value
stream mappings

 Calculate OEE for individual machine and improvise its output to 85%
 Preparing standard operating procedures display them in local languages for all critical operations.
 Establish a defect gallery room to train operator, bring quality awareness and how to avoid them.
 Study and improve FTY of compressor assembly to 95% through process improvement projects
 Avoiding final product quality checking through manual interventions. Ex: Identifying abnormal sounds
in the product final testing which is done manually and purely skill dependent. To avoid it an online
noise testing equipment has been implemented to detect any abnormal sounds or higher Db levels

 Implement kaizens and get tangible and intangible benefits out of it.
 Raising Engineering change orders and seek approvals in the oracle for any manufacturing change
processes

 Update routings in the oracle for new product or an item code.

 Clarifying the queries raised by Tecumseh Indian Ballabgarh Works plant in Oracle routings and
document those for future training or reference.
New product Development: Functional Team member in new product development project, update project
status in MS project to the Global Programme Manager.

Investment Study for Projects: Project capital estimation, Raising RFQ’s, Technical discussions, Negotiations
& Signoff with supplier, Raising Capital Expenditure Requests to new equipment’s and seek approvals from
India and Global functional heads prior to product launch readiness.

Standardization: Displaying standard operating procedures at each & every critical to quality & critical to
process areas prior to reduction of end of line rejection ppm.

Process Improvement Projects:

 Improving production rate of compressor assembly from 2500/day to 3000/day, which comes under
key improvements to achievements.

 Reduction of in-process rejections from 30% to 15% through complete machine & process changes.
 Reducing compressor End of Line ppm from 25000 ppm/month (as on May’13) to 1800ppm in current
year and month

 Identifying & elimination of wastages in shop floor using Value stream mapping.
 Implemented SMED in process tube resistance welding which improved productivity from 74% 86%.
 Implemented poka yoke in resistance welding machine to avoid wrong loading of component and
breakdown of the machine

 Converting idle stator and rotor assembly machine (machine cost Rs: 8000K) from one variable to
running model assembly, thus avoiding yearly depreciation of the machine, improve throughput from
700/shift to 1200/shift.

 Commonisation of assembly tools of stator and rotor assembly machines to avoid, thus enabling
exchange of tools between two machines when one is running down and also avoid confusion while
ordering tools.

 Reduced tools consumption in the above assembly machine by modifying tools, hence reducing tool
consumption from 9 per year to 2 per year and improve conversion cost. Each tool costs Rs:4500/-

 Disintegrating assembly line to pre and final assembly to reduce model mixing, mismatch, quality
defects by 24% , improved output from 850/shift to 1100/shift and reducing 2 headcounts.

 Installed kit torque tester equipment to measure torques & thus improved product EER from 0.07 by
reducing starting torque from 4.1oz.in to 2.1oz.in and run torque from 2.5 oz.in to 1.4 oz.in

 Improved compressor surface treatment plant capacity from 2700/day to 5400/day in May’2016
 Current project is to implement powder coating plant over dip painting process. Improve aesthetics of
product and customer satisfaction. Eliminate yearly paint wastages, disposal and maintenance cost of
Rs: 17.8 lakhs.

Layout Improvement: Executing TOPS in Re-layouting of whole Assembly area with the concept of single
piece flow & Reduction of power load on AC. Space Saving of more than 30% of Assembly Area & Reduced unit
price per compressor & Smooth flow of components.
Recently in the month of Oct’15 a new layout has been made to manufacture new product (AE 2) of
800Kvolumes per Year, in existing line (AK) without stopping existing model production. Layout has been
approved by Global heads, though the project implementation has been put on hold to 2018.

Capacity standardization: Define its TAKT time & manpower after doing time study & analysis.
Capacity Improvement: Identification of bottlenecks & constraints in entire production chain and improve
process through value stream mapping as per lean principles.

Material Handling Improvement: Prior to end of line ppm compressor rejections due to component
damages, material handling method changes in line by eliminating manual handling of components and so
reducing component damages.

Workstation design & Maintenance:

Developed ergonomically designed workstations to reduce the fatigue of operators & maintenance work to meet
lines target without any loss.

5S:
Training to operators to make them aware of 5S.
Zone owner for maintaining 5S.

Quality Control Circle:

Facilitator for a Quality control circle Team (Tecumseh Innovators) which stood 3 rd in First Telangana State
Level Convention Competition on Quality Control Circles in 2014.

Layout Improvement & Design:

Working on reduction of manpower through layout changes & balancing line as per TAKT time & standard hours

Productivity improvement:
Line Balancing of Assembly lines by using Industrial Engineering Tool Time study & equally work distribution as
per the TAKT time based on study & analysis.
Productivity Improvement by reducing various Non value added activities found during the Work measurement
study. Productivity Improvement By 10%.
Implementation of KAIZEN ideas to attack the bottleneck processes, as to improve the capacity & combination
of operations results into manpower saving.

Technical Skills:

Tools: Oracle R12.1.3 Manufacturing module (Inventory, BOM, WIP, Costing & Order management), Auto
CADD, MS Project & office 2013.

Trainings Attended on:

TOPS (Tecumseh Optimized Production System) Monthly Schedule

ASCP (Advance Supply chain Planning) by Amit from Delloite (10 day Duration)
FMEA (2 Days Duration)
Team Building, Positive attitude & Communication skill Training by corporate trainer ‘Mr. V. Srinivasa Rao
(6 sigma Black belt holder)

Qualification Year Institution University Percentage

2007-10 Aurora’s Engg College, Bhuvanagiri,

B.Tech. (Mech.Engg) JNTU 62%
Nalgonda
Diploma Sanjay Gandhi Memorial Govt.
2004-07 SBTET 62%
(Automobile Engg.) Polytechnic, Abdullapurmet, Hyderabad
SSC 2003 Amaravathi Grammar High School SSC
55%

Academic Engineering Projects:

 Design and Manufacturing a Prototype Humanoid Robotic Arm

 Aerodynamic Study on Centrifugal Air Compressor Using Computational Fluid Dynamics
(Fluent & Gambit)

PERSONAL DETAILS:
NAME : KANNAIYAN UDAY KUMAR
DATE OF BIRTH : 07-05-1987
CITIZENSHIP : INDIAN
SEX : MALE
FATHER’S NAME : SHRI. K.VIJAYA KUMAR
MOTHER’S NAME : SMT. K.MANI RANI