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Setty purushothaman - Lean Manufacturing - Hounslow, Greater London, UK

Murugan Setty purushothaman

Hounslow, Greater London, UK


Lean Manufacturing


*PQ/PR analysis, Time observation form, Process capacity table, Standard Work Sheet, Standard work combination sheet and operator loading chart

*Batch quantity and No of setup calculation for shared process

*Heijunka,Jidoka,Andon,FPY,COPQ and DM

Work History

Assistant Manager-Purchase and Vendor Development

Bonfiglioli Transmission private Limited

June 2011 - February 2014

 Supplier selection and evaluation by audit through sourcing tools(RFI, pre Assessment, RFQ, Market test)
 Price contract fixation and relevant document preparation for management approval
 Investment details preparation and get approval from management
 Development of investment item
 Po release and follow-up with supplier
 Invested item transferred to supplier and maintaining tracking for future reference
 SCR raising if supplier cannot meet specification
 PPAP documents creation support to Supplier(PSW, PFMEA, Control Plan, MSA, Process capability study, etc…19 elements)
 PPAP Documents maintaining for future & customer reference
 Supplier Annual Audit
 Sending Monthly Supplier performance rating and getting feedback from supplier
 Co-ordination with supplier for any CAPA (8D)
 Paynter chart preparation to track countermeasure effectiveness
 Lean concept implementation at supplier end and giving training to them for their better understanding (2Bin concept, Milkrun, Quality in built process at cell etc..)
 Sending weekly in-warding material report to concern supplier for their reference
 Conversion of pending PR to PO and follow up with supplier for timely delivery
 ATP confirmation giving to planning for customer commitment
 Inventory level monitoring against order
 Commodities are handled castings, forging, Machining and Gears
 Working for ISO audit
 ERP used SAP

Senior Engineer-Lean Manufacturing Engineering

Gilbarco Veeder-Root

October 2009 - May 2011

 Cell Design through PQ/PR analysis
 Calculating takt time, Fixing curtain Qty for bottle neck operation
 Making Standard work documentation(Time observation form, Process capacity table, Standard Work Sheet, Standard work combination sheet and operator loading chart) and PFW, PFMEA, Control Chart and SOP
 Making production schedule by heijunka method
 Calculate First pass yield and create error proofing method by jidoka(Poka Yoke)
 Calculating 5 cost of COPQ
 Daily Management preparation and updating for Gemba meeting
 Conduct Kaizen for small improvement
 Create CVSM for process/Product line
 Identify waste
 Lean Tools implementation for waste elimination
 Create FVSM for comparison and future action
 Facility Making of new established line as per kaizen
 Making manufacturing BOM
 ERP used SAP

Engineer - Supplier Quality Assurance

Lakshmi Machine Works Ltd -CNC Division

May 2005 - September 2009

 Evaluating the potential of new supplier and regular audit with existing suppliers.
 APQP tracking for the sourced parts and co-ordinates with sourcing for part readiness.
 Providing technical Clearance and guidance to the Supplier team to achieve results.
 Conducting Run @ rate to access supplier capacity and monitoring the process capability for CTQ at supplier end (SPC).
 Approval of supplier parts as per PPAP procedures.
 Process and Product audits of assembly lines
 Handling of supplier Complaints through CAPA (8D) problem solving techniques.
 Developing Agreement of Inspection (AOI) and Part Quality plan (PQP) for purchased parts & ensuring all CTQ parameters are addressed in the supplier control plan.
 Ensure quality system at supplier end for consistency of product process performance.
 Initiating process improvements and Poka-yoke for the existing process.
 Monitoring of supplier quality performance and for timely resolution of any product problems reported on supplied parts.
 Monitoring / follow-up with supplier for continuous improvement plan.
 Implementing DOL (Direct on line) Concept for Supplier parts.
 Taking responsibility for Customer / Third party / Internal Audits.
 ERP used ORACLE 11i


Lean Implementation

* Create Current/future state VSM For LL BED

*Housekeeping in TOOL CRIB through 5’S Concept

*Setting MIL for SCM SUPERMARKET(2 bin concept)

*Deep hole drilling machine Set-up time reduction through SMED

*Concept of KANBAN CARD

*Milk-Run concept established for material collection from local supplier

JIT Manufacturing

I did JIT manufacturing project while doing M.S Manufacturing Mangement

Qualifications & Certifications

Master of Science

Birla Institute of technology and science

Bachelor of Engineering

Anna University

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