Expert Details

Expert in Injection Molding Projects from Design to Productionizing, On Site Training & Efficiency Improvement

Expert ID: 730755 India

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Expert, a practicing consultant in the plastics field offers specific and customized solutions to the needs of the clients especially in the injection molding segment.
With more than 28 years of experience in the industry, having worked on global assignments all along, with in-depth knowledge from concept to reality and wide networking capabilities.
With his expertise in cost control methods and measures, he delivers customized formulas for operational efficiency.
He has been handling many projects in product development, productivity enhancement, energy savings structured creation of knowledge pool in big companies .
He imparts functional knowledge at all levels in the molding industry and raising levels of decision making capabilities at all levels.

He has designed function based training modules starting from machine operator through supervisory, managerial cadres apart from specific programs for tool designers and business owners.

He has the capability to train the managers for profitable process planning, decision making and implementation.

He teaches methodical approach on new product design and development of new business

He also trains buyers on effective supplier selection, qualification apart from successful procurement methodology at the right cost, quality and reliability.

He offers project assistance in the following areas.

a)Specific projects on New Product Development

b )Identify and reduce waste & improve productivity improve operational efficiency / Energy Efficiency

c) Global Supplier identification / selection / development

d) Improve Functional Awareness at all levels through continuous training programed

e )Developing KPIs for every function for effective performance assessment


A).He took total charge of a project in 2008-2009 for installing / commissioning a new factory for manufacturing PET preforms for water and CSD apart from closures starting from equipment selection techno-commercial negotiations plant lay out ( end to end ) that runs successfully and profitably .
B ) He took active part in a global project ( 2003 - 2004 ) in developing customers for the manufacture of BOPP laminated woven bags for food and pet- food packaging applications. This involves detailed involvement of developing the products to customer's specifications establishing process sytems and standards in the extrusion lamination printing and bag making lines .

C. He took charge of a project for establishing process standards by optimizing the process inputs and equipment design for thin walled packaging for a Malaysian customer . Earlier this process was running with lot of inconsistency and unacceptable rejection levels and scrap generation 2009-2010 :He has assisted a key customer who was supplying injection molded assemblies to a large volume liquor company . The product involved totally 16 identical molds ( 2 cavity each ) for the same part . The challenge was to get all 16 x 2 = 32 cavities produced from 16 machines same in terms of dimensional consistency and functional performance . These 32 parts do get assembled with containers from multi cavity molds . The permutation and combination of the cross cavity matching was enormous that posed the challenge of fitment and functional consistency . He streamlined a structured and disciplined molding process methodology with an acceptable operation window and established the process engineering standards .2001-2002:He was fully involved in a electrical switch manufacturing project with more than 100 designs in terms of machine, mold & material selection establishment of process parameters for successful productionizing . He also participated in implementing a structured trouble shooting methodology for the entire spectrum of molding for the switch molding project 2010-2012 He has handled many projects for improvement of operational efficiency that involves productivity improvement ( around 18 to 20 % ) which helped save significant investment costs on capital equipment and tools . Also this resulted in a enery saving of around 12 % a manpower reduction of 15 % and material saving of 5 % .2006-2007 :He has designed many customized screw designs for specific materials for effective high volume production with low rejects which had been a challenge to the molder . He has suggested appropriate changes in the tool design machine configuration and process design that helped the molder to come out of most of the process and quality related issues .

Education

Year Degree Subject Institution
Year: 1981 Degree: Degree in Applied Science Subject: Applied Science Institution: Madurai Kamarajatr University
Year: 1984 Degree: Post Graduate Diploma in Plastics Technology Subject: Plastics Processing Technology Institution: Central Institute Of Plastics Engineering & Technology , Chennai India
Year: 1988 Degree: Post Graduate Diploma in Statistical Quality Control Subject: Statistical Quality Control Institution: Calcutta University

Work History

Years Employer Title Department Responsibilities
Years: 2008 to Present Employer: Undisclosed Title: Senior Consultant Department: Responsibilities: He has been operating as an industry consultant for the last 5 years independently on global projects and assignments on new product new suppllier developments and supplier qualification assignments
Years: 2006 to 2008 Employer: Taylors' Engineering Pvt Limited Title: Director Department: Operations / Marketing Responsibilities: He was responsible for new product development and marketing of injection molding and extruder machines.
Years: 1993 to 2006 Employer: Larsen & Toubro Limited Title: Head of Application Engineering and Customer Service Department: Plastics Processing Machinery Responsibilities: He was heading a team of Application Engineers and Customer Service Engineers working for the Plastics Machinery Division which was the leader in the segment . He was offering complete solutions to customers on the application needs . He was also the interface between the market and manufacturing on the application and product quality segments .
Years: 1988 to 1993 Employer: Sundaram Plastics ( Harita) Title: Head of Production & Planning Department: Molding Division Responsibilities: He was taking care of production in the first phase later got elevated to head production planning plat engineering and new produc development
Years: 1985 to 1988 Employer: Impact Plastics Limited ( unit of P&G ) Title: Production Engineer Department: Packaging Division Responsibilities: He was responsible for new plant set up and productionizing . He headed a team of supervisors & operators in molding and printing sections .The unit was supplying packaging ( rigid and flexible ) to the medical division of P&G
Years: 1985 to 1986 Employer: Malhotra Shaving Products Title: Molding Engineer Department: Production Responsibilities: He was managing shifts in the molding and assembly areas.
Years: 1984 to 1985 Employer: Kanpur Plastipack Limited Title: Trainee Engineer Department: Production & Maintenance Responsibilities: Started the career as a trainee engineer in this company in the extruder division who are flexible packaging suppliers to cement agro and fertilizer industry

International Experience

Years Country / Region Summary
Years: 2009 to 2010 Country / Region: China Summary: A )He took charge of a successful Project in China for product development on liquor dispensing system that involved development and qualification of 16 identical moulds.
B)He also conducted audits with few other big manufacturing units in line with global demands and standards on the entire spectrum of activities.
Years: 2012 to 2012 Country / Region: Vietnam Summary: He conducted company wide audit on manufacturing systems and procedures in line with global needs for food and non food packaging applications and suggested corrective measures for improvement .

Years: 2003 to 2003 Country / Region: Malaysia Summary: He was actively involved in establishing process standards for thin walled moudling for trouble free process and defect free environment
Years: 2011 to 2012 Country / Region: China Summary: He established systems for structured and methodical New product and new mold developments and documentation,for a medium size molding unit manufacturing appliances .

Also he introduced structured methodology for process trouble-shooting improving profitability in molding operations reduce rejection levels on thermoset moldilded parts
Years: 2009 to 2010 Country / Region: India Summary: He took lead role in establishing and commissioning PET preform & closures plants as a turn key set up . He has also successfully conducted almost 150 training programmes for various customers on various topics in the injection molding industry.

Career Accomplishments

Associations / Societies
He has been a member of Society of Plastic Engineers ( SPE ) after the Chennai chapter was inaugurated.
Publications and Patents Summary
He has published many articles in the national technical journals for plastics . He also has been part of team developing new concepts in injection molding machine technology . Some of them have been patented by the company .

He had presented Papers on Injection moulding conducted by SPE India in 2004 on Efficiency in Injection Moulding .

He presented paper at CII Delhi in 2006 on Advances in Injection Moulding Technology

Also he published papers on the following at different occassions .

1. Role of Mould Temperature Control in Injection Moulding
2. Thermoset Injection Moulding
3. Advanced Injection Moulding technoilogy
4. Efficiency in Injection Moulding
5.Staying fit for global moulding demands

Language Skills

Language Proficiency
English

Fields of Expertise

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