Yoga
MUTHUKRISHNAN PALUSAMY
PROFESSIONAL WITH EXPERIENCE IN OPERATIONS, PRODUCTION, PRODUCTION PLANNING, CONTINUAL IMPROVEMENT IN MANUFACTURING INDUSTRY.
Ras Al Khaimah,Ras Al Khaimah
Summary
Operations and Production Management Professional experienced in driving operational efficiency and process improvement within manufacturing environments. Led teams to achieve measurable outcomes through strategic planning and team collaboration. Focused on fostering a culture of accountability and adaptability to meet evolving organizational needs.
Overview
3
3
Languages
2
2
Certifications
22
22
years of professional experience
Work History
Manager-Project/Production
Caresoft Technologies LLC
04.2025 - Current
- Led end-to-end vehicle benchmarking and teardown programs across U.S., European, and Chinese OEMs, delivering 30+ projects on time and within budget.
- Managed cross-functional teams PMO, Sales, 3D scanning, mounting strategy, location, and quality to achieve the project deliverables
- Directed full vehicle and subsystem teardown activities, including powertrain, chassis, interiors, and electronics, generating actionable engineering insights. (Teardown, BOM, M&M, Photography, species, Weight tally, Data Harmonisation)
- Identified cost optimization opportunities through teardown analysis, contributing to significant BOM cost reductions, and improved design efficiency.
- Established standardized teardown and benchmarking methodologies, improving analysis accuracy, and reducing project turnaround time.
- Utilized advanced tools and data analytics to compare vehicle performance, durability, and manufacturability across global markets.
- Performed end-to-end validation of PCRs and GAB approvals, reducing errors, and improving process efficiency, Customer requirement implementation in the product.
- Lead 120 team members.
- Led cross-functional teams to enhance project delivery and operational efficiency.
- Streamlined processes, reducing turnaround time for project approvals and implementations.
- Mentored junior managers, fostering professional development and leadership skills.
- Implemented key performance indicators to monitor team productivity and effectiveness.
- Collaborated with stakeholders to align business objectives with technology solutions.
- Conducted regular performance reviews, driving accountability and continuous improvement.
- Managed and motivated employees to be productive and engaged in work.
- Accomplished multiple tasks within established timeframes.
- Maintained professional, organized, and safe environment for employees and patrons.
- Controlled costs to keep business operating within budget and increase profits.
Production Manager
IQON Automotive FZ LLC
09.2024 - 04.2025
- Led end-to-end vehicle benchmarking teardown programs for U.S., European, and Chinese OEM vehicles, successfully delivering over 30 projects on time and within budget.
- Managed cross-functional teams across PMO, Sales, 3D Scanning, Mounting Strategy, Location, and Quality to analyze competitor vehicles, identifying actionable performance, quality, and cost improvement opportunities.
- Directed complete vehicle and subsystem teardown activities, including powertrain, chassis, interior, and electronic systems, generating actionable engineering insights through teardown analysis, Bill of Materials (BOM), Material & Measurements (M&M), Specious, Attribute data collection, Parts photography, weight tally, and data harmonization.
- Identified cost optimization opportunities through detailed teardown studies, enabling BOM cost reductions and enhancing overall product design efficiency.
- Developed and standardized vehicle teardown and benchmarking methodologies, improving analysis accuracy and decreasing project turnaround time.
- Performed end-to-end validation of PCRs (Process Change Requests) and GAB approvals for improving process accuracy, and reducing error, effort reduction and new process implementation.
- Planned manpower capacity, prepared bespoke project estimations, and led the recruitment of engineering professionals.
- Led and mentored a multidisciplinary team of over 120 engineers and technical professionals, driving project execution, operational excellence, and continuous process improvement.
Sr. Engineer - Planning
Sobha Modular LLC
11.2023 - 07.2024
- Coordinated with customers to ensure alignment on delivery schedules, production status, mock-ups, and specification confirmations.
- Ensured project readiness by verifying specifications, technical drawings, Bills of Quantities (BOQ), Purchase Requisitions (PR), Local Purchase Orders (LPO), and supplier order confirmations.
- Planned and scheduled production activities, and supplier deliveries, to meet project timelines.
- Tracked material availability to ensure uninterrupted daily production, and support project timelines.
- Prepared Management Information System (MIS) reports, and contributed to production planning meetings to enhance project execution.
- Coordinated with cross-functional teams, including Procurement, Estimation, Production, and Stores, to ensure smooth project execution.
- Implemented material rejection and reorder processes to minimize production delays.
- Oversaw casting operations, LGS assembly, 3D assembly, floor and wall tile assembly, MEP, structural assembly, and final fitting activities by defining cycle times and optimizing manpower allocation.
- Implemented supplier, incoming material, and in-process production material rejection procedures to improve quality control.
- Identified critical quality issues and established an in-house material trolley system to improve material handling and workflow.
- Supported ERP (Odoo) implementation by coordinating with internal teams, facilitating process integration, and assisting with system deployment.
Manager- Production
Scuderia Motors Design LLC
07.2020 - 10.2023
- Plant in charge of luxury and armoring vehicle interior customization, carpentry, plumbing, fabrication, FRP product, upholstery, painting, wood veneer and carbon fiber, electrical, final assembly, and testing.
- Scheduled production and planned materials to align with operational goals.
- Prepared a bill of quantities for project estimation.
- Achieved production targets by optimizing workflow processes.
- Project progress tracking and action tracking.
- Project progress tracking and action-taking.
- Operational budget cost vs. actual cost comparison and action for the abnormality.
- Prepare a manpower plan and recruit the manpower as per the plan.
- Sourcing suppliers and contracting procedures.
- Planning and implementation of plant expansion activities.
- Ensure the ISO standards are adhered to, and on-time audits are conducted.
- Standardize the materials, tools, and processes.
- Executing the capacity improvement plan and execution.
- Tracked monthly production costs and optimized expenditures to maintain budgetary targets.
- Customer compliance, rectification, and initiation of permanent corrective action.
- Creating operational policy and procedures.
- Processed employee salary increments based on performance evaluations.
- Created operational policies and procedures to enhance efficiency and compliance.
Sr. Engineer - Planning
ASHOK LEYLAND LLC
11.2017 - 06.2020
- Responsible for monthly sales order acquisition from the Marketing team and coordinating with Production team for timely delivery of vehicles to respective dealers
- Acquired monthly sales orders from the Marketing team and coordinated with the Production team for timely delivery of vehicles to respective dealers.
- Prepared and executed plans for both export and local distribution, generated daily sales MIS, and created monthly FG reports.
- Strong experience in exporting to various countries such as Saudi Arabia, Oman, Bahrain, Qatar, Kuwait, Ghana, Congo, and Senegal.
- Coordinated with shipping and transport agents to confirm schedules and documentation for vessel and trailer shipments, ensuring compliance with delivery timelines
- Coordinated with Shipping and Transport agents to confirm schedules and documentation for vessel and trailer shipments
- Prepared local and export vehicle customs and legal documents in compliance with legal requirements, including VCC, COO, SASO, and MOE
- Collaborated with various internal teams, distributors, and logistics providers to arrange port handling process documents
- Conducted monthly FG inventory stock counting and monitoring, investigated transportation damages, recommended corrective actions, and cleared payments for shipping lines, transporters, third-party drivers, and legal document agents.
- Accountable for monthly FG inventory stock counting and monitoring, investigating transportation damages, recommending corrective actions, and clearing payments for shipping lines, transporters, third-party drivers, and legal documents agents
- Monitored yard stock vehicles and conducted quality checks.
- Compiled detailed report on aging vehicles for management review
Deputy Manager - Production
RANE TRW STEERING SYSTEM
05.2017 - 11.2017
- Managed production for seat belt and airbag assembly lines to oversee customer orders for dispatch and ensured materials aligned with the production plan.
- Met customer expectations for quality and on-time delivery for clients including Ford, Daimler, TATA, M&M, Fiat, and Maruti.
- Tracked and monitored plant OEE, approved ECN parts, conducted process audits, cleared customer NCs, and made robotic containment actions.
Production Engineer
KIA MOTORS CKD ASSEMBLY PLANT
08.2015 - 08.2016
- Prepared assembly line layout and delegated work based on process specifications.
- Led the line for passenger car (Picanto/Rio/Certo/Optima/Carens) and commercial pickup truck (K2700/KZ700DC/K4000S) in DKD Production & Quality with a team of 10 Iraqi Supervisors and 80 Associates.
- Skillfully interpret assembly drawings and planned production activities based on warehouse stocks/sales requirements.
- Liaised between Iraqi SCAI production team and KIA management to meet production targets while maintaining a safe work environment for personnel and machinery on the shop floor.
- Handled all incoming inspections and scrap review activities along with vehicle torque audits and quality gate inspections; troubleshoot all process-related issues and monitored product quality on a daily basis; implemented process sequence and assembly feasibility studies in the shop floor.
- Oversaw incoming inspections, scrap reviews, vehicle torque audits, and quality gate inspections; troubleshot process-related issues and monitored product quality daily, implementing process sequences and conducting assembly feasibility studies.
- Analyzed packaging issues through effective RCA and provided feedback on sourcing/replacing/ordering parts.
Production Manager
NISSAN MOTORS CKD ASSEMBLY PLANT
09.2014 - 04.2015
- Entrusted as Line In-charge for Pickup truck D22 assembly and repair line assisted by 32 Associates and 2 Nigerian Supervisors ensuring the team achieves production as well as quality targets.
- Generated reports analyzing CKD part damage and quality defects, identifying functional issues for resolution.
- Oversaw shop floor management, implementing 5S, conducting sunrise meetings, reviewing scrap, improving assembly processes, purchasing new tools and equipment, leading safety training for technicians and supervisors, and appraising team performance.
- Earned a reputation for efficiently handling all Nissan models Almera, Patrol, and D22 Pickup Truck in the repair line gaining strong expertise in Nissan consult diagnostics.
- Coordinated shop floor meetings with Nissan Ashok Plant team to address non-moving FG and enhance CKD operational excellence.
Sr. Engineer - Production
DAIMLER INDIA COMMERCIAL VEHICLE PVT LTD
03.2011 - 09.2014
- Accountable for station development activities, including design work, station layout, tool/equipment/process sequence, assembly producers, training new joiners, etc.
- Efficiently handled trim assembly line setup and production start activities, including line layout marking, tooling, barcode scanner, crane, conveyor, MES panels, jigs/fixtures, VIN punching machine, etc.
- Managed shop floor activities, including Andon board, Kanban, build card, and TPM check sheet, to streamline operations and enhance workflow efficiency.
- Planned new models, oversaw truck proto build activities, and configured build sheets for new variants/models.
- Involved in planning for new models, overseeing truck Proto build activities, and configuring build sheet for new variants/models.
- Conducted training sessions and audits on waste disposal management and consumable/safety material usage, fostering a culture of continuous improvement through participation in Kaizen competitions.
- Validated new model BOM, allocated processes, managed manpower allocations, addressed quality issues, conducted cycle time studies, and balanced lines.
- Generated internal and external quality audits, created FQT customer quality issues feedback forms, and implemented prompt resolutions and corrective actions.
- Conducted RCA for line-side part fitment issues and managed paint scratches/dent prevention activities.
- Implemented assembly line actions and performed annual cycle count activities for WIP, ensuring inventory accuracy and operational efficiency.
Vehicle Launch Member
FORD INDIA PVT LTD
04.2004 - 03.2011
- Hands-on experience in Trim, chassis and engine assembly, repair & inspection.
- Development of Standard Operating Procedures, Visual aids, Single point lesson, etc.
- Initiated improvement projects that enhanced overall productivity.
- Conducted time & motion study (MODAPTS) to analyze processes and optimize line capacity.
- Identified value-added and non-value-added activities, along with waste, to streamline processes.
- Re-layout proposal to the process team for eliminating the NVA's
- Sought opportunities to implement jigs and fixtures for enhanced production efficiency.
- Created value stream mapping to identify future state improvements.
- Reduce quality & safety issues through the formation of a Natural Work Group (NWG).
Education
MBA - Production & Project Management
IIBM institute of Business Management
Bachelor's degree - Electrical & Electronic Engineering
Singhania University
Diploma - Electrical & Electronic Engineering
Annamalai Polytechnic
Skills
Production planning
Quality auditing
Lean practices
Cycle time analysis
Line balancing
Waste reduction
Teardown benchmarking
Automobile Production
Trim and chassis production
Engine & Final
Assembly expertise
Process documentation
Rejection/Repairs/Diagnostics
Analysis
Team leadership
Decision-making
Time management
Communication skills
Problem solving
Customer service
Verbal and written communication
Complex Problem-solving
Goal setting
Strategic planning
Project management
Key performance indicators
Certification
Lean Six Sigma black belt certification | ICQ-499 | ICQBS
Interests
Cricket
Leaning Lean practices
NOTEWORTHY CREDITS
Received the Best Problem-Solving Award at Ashok Leyland for reducing non-moving finished goods (FG), Reduced project lead time from 90 days to 45 days at Scuderia Motors, improving project execution efficiency., Successfully expanded manufacturing capacity, increasing production output by 200% at Scuderia Motors., Led the successful implementation and certification of ISO 9001:2015 at Scuderia Motors., Honoured with the Best Team Achiever Award at Daimler India for outstanding contributions to Supplier Quality Development (SQD), continuous improvement, and 5S initiatives., Received the Best Performer Award and Best Kaizen Award at Ford India for excellence in operational and process improvements., Successfully led three greenfield manufacturing projects across India (Ford and Daimler), Nigeria (Volkswagen SKD Plant), and the Middle East (Kia Motors, Iraq), delivering all projects within agreed timelines.
Timeline
Manager-Project/Production
Caresoft Technologies LLC
04.2025 - Current
Production Manager
IQON Automotive FZ LLC
09.2024 - 04.2025
Sr. Engineer - Planning
Sobha Modular LLC
11.2023 - 07.2024
Manager- Production
Scuderia Motors Design LLC
07.2020 - 10.2023
Sr. Engineer - Planning
ASHOK LEYLAND LLC
11.2017 - 06.2020
Deputy Manager - Production
RANE TRW STEERING SYSTEM
05.2017 - 11.2017
Production Engineer
KIA MOTORS CKD ASSEMBLY PLANT
08.2015 - 08.2016
Production Manager
NISSAN MOTORS CKD ASSEMBLY PLANT
09.2014 - 04.2015
Sr. Engineer - Production
DAIMLER INDIA COMMERCIAL VEHICLE PVT LTD
03.2011 - 09.2014
Vehicle Launch Member
FORD INDIA PVT LTD
04.2004 - 03.2011
Diploma - Electrical & Electronic Engineering
Annamalai Polytechnic
MBA - Production & Project Management
IIBM institute of Business Management
Bachelor's degree - Electrical & Electronic Engineering
Singhania University