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Kamalanathan M Jayaram

Manufacturing Engineering Manager

Summary

Driven Engineering Manager with 13+ years experience coordinating manufacturing tooling/processes and Engineering department of 82 direct report's through planning and execution. Performed process improvements and ongoing cost reduction activities resulting in successfully meeting goals and saving millions of dollars per year. Thorough understanding of process & maintenance aspects and safety standards. Superb balance of technical know-how with workforce management and collaborative abilities. Earned reputation as a hard charging leader with distinctive ability to train and lead efficient, goal-focused teams. 

  • Career Objective: To continue pursuing various high level positions in engineering and management fields. Besides that, fully utilize the skills which I have obtained and continue to motivate and challenge myself with new engineering & management knowledge. High-energy, confident professional with a contagious enthusiasm for technology.

  • Future plans: To equip myself with the managerial competencies, which will enable me to hold top management position, develop and carry out strategies plan, work as a team and lead the organization dynamically which will further empower the company to face the challenge in the new millennium into a learning organization.

Work experience

Oct 2018Present

Manufacturing Engineering Manager - Headstack

Western Digital Malaysia – PJ, Selangor

Managed all engineering personnel and personally led sustaining and development programs by providing forecasting, direction and guidance to the process group on strategy, expense planning, goals and objectives.
Successfully achieved key engineering indicators such as assembly yield, cycle time, scrap rate, SPC indicators.
Managed and executed engineering support for all process associated of headstack assemble.
Manage and conduct regular staff meeting and keep documentation on the area activities via weekly Engineering reports.
Managed and upkeep document integrity for all Process/Tooling Engineering specs in-line with ISO requirement.
Held regular review the forecast of key process parameter such as assembly yields, cycle time, Cpk’s, PPM’s, scrap cost to achieve process, department and company quarterly goal. Made recommendation for appropriate decision to balance goal achievement between the goals.
Reviewed the forecast for process engineering expenses budget and managing cost to achieve department budget.
Evaluated and implemented processes and assembly changes utilizing vehicles such as Engineering Bulletins, MCO’s. ECO’s.
Regularly liaise with counterpart organization in other sides for joint engineering decisions to matters pertaining to process changes and engineering specifications
Formulated and continuously improved new and renovated facilities, equipment and processes under responsibility are safe and comply with ISO requirement, Safety rules and regulations.
Planned and coordinated new product and technology transfer between work sites and meeting in process related issue.
Provided coaching to staff and improved effectiveness and efficiency of working methods on new projects. 
Subordinates (82 Direct Report’s) ; Engineers (13), Technicians (47) and Engineering Operators (22). Lead a group of team by guides them in technical knowledge to support manufacturing to perform theirs job with efficiency and effectively.

Accomplishments:

  • Value Engineering’s Mission: Successfully completed cycle time reduction.
  • Value Engineering’s Mission: Successfully completed yield improvement.
Jan 2007Sep 2018

Manufacturing Engineering Manager - Hard Drive

Western Digital Malaysia – PJ, Selangor

Managed and continuously improved all process and tooling related issues by maintaining process and tooling knowledge, manufacturing troubleshooting and issuance of instructions to production on manufacturing
Developed and designed, processes and tooling designs to the method of manufacturing of the factory's product.
Successfully developed and qualify new processes and products which assigned to me in areas of transfer activities, process set-up and subsequent proliferation.
Managed and reviewed daily tooling issues in containment actions and subsequent long term engineering solutions.
Successfully achieved key engineering indicators such as assembly yield, cycle time, scrap rate, SPC indicators.
Value Engineering’s Mission: Successfully completed cycle time reduction and yield improvement project for new and sustaining products.
Process Engineering Department Financial Controller : Manage all aspects of the financial planning and reporting functions of the department. Prepare weekly, monthly, quarterly reporting, budgeting and forecasting.
“6S” Team Leader and Task Force Team : Handle FMEA meetings to discuss production, process and tooling issues highlighted by customers/production during audits and come out with corrective and preventive action.
Factory Main Project Team 2009 : Developed process layout for new plant (P6) setup for mobile product manufacturing support, actively involve in line setup and process qualification from BE assembly to shipment.
New Plant Setup, WD Brazil Project 2011: Planned and coordinated new manufacturing line setup at Manaus, Amazonas, Brazil – Provide support for tooling and process by setting up assembly tools, validate new processes, technical support, training for Brazil supporting team such as engineers and technicians and line performance monitoring for 6 months.
Backend Automation Project 2013: Converted manual labeling process and manual drive packing system into fully automation process. Reduce man power (31 Head Count), labor cost (USD 53K per qtr and USD2.3 per year), space and improve productivity (30K output per day) by reducing cycle time (20secs to 2secs).
Cost Saving Projects 2014: Contributed to PCB scrap improvement 90% per quarter. The actual scrap posted drop from $500K to $50K per quarter.
WDM Innovation Day 2015: 1st project top 5 finalist ; 2nd project top 10 finalist.
New Product Transfer 2015 : Completed process optimization for new product and technology transfer “Helium for Life 6TB Product” from Western Digital San Jose California (R&D).
Value Creation Program 2016: Outstanding Recognition / Contribution Award for exemplary leadership, extraordinary determination, teamwork and contribution to achieving the “Site Efficiency Improvement” USD 21.5M/year DL Cost Saving in HDD Value Creation Program.
Inventory Turn & Cash Improvement Project 2017 : Recognition Award for BEA Deployment and Utilization Improvement
Continuous Improvement Projects 2018: CI Award for dedicated contribution towards value creation and optimizing operation efficiency “Operation Efficiency Improvement” with total saving of USD 2.2M/qtr (Q3-Q4’18).
Subordinates (40 Direct Report’s) ; Engineer (2), Technical Specialist (3), Senior Technicians (9) and Technicians (26). Lead a group of team by guides them in technical knowledge to support manufacturing.

Accomplishments:

  • “Operation Efficiency Improvement” with total saving of USD 2.2M/qtr (Q3-Q4’18).
  • Recognition Award for BEA Deployment and Utilization Improvement
  • “Site Efficiency Improvement” USD 21.5M/year DL Cost Saving in HDD Value Creation Program..
Jan 2006Jan 2007

Mechanical R&D Engineer

Panasonic Compressor R&D Center - Shah Alam, Selangor

Developed and designed  the total cycle of compressor R & D design and development activity including idea/concept development, planning, scheduling, designing, testing & analysis, application and market quality.
Successfully managed and provide quality engineering support to manufacturing processes and product changes.
Managed engineering support to production to sustain and improve production yield, quality and process cycle time.
Completed all engineering documentations related to assigned projects such as plans, technical reports, technical drawings and manufacturing standard operation procedures.
Determined and designed new product specification and work closely with Production and QA departments during the pre-production planning and testing as well as the mass production stage. Identify potential production problems and rectify all issues and concerns before mass production.
Develop Bill of Material (BOM) on new product specification, processes, cycle times and packing requirements are complete before production commences.
Identified, recommended and lended product improvement exercise through Self Development Project (SDP) to enhance efficiency and quality.
Lead project teams in the development, verification, validation and submission of new products. Interface with all departments participating in the development timelines to meet milestones.

Accomplishments:

  • New launching of 2KS282H Hero K Air Cond Compressor in Middle East

Education

20072009

Masters in Business Administration (MBA)

Universiti Teknologi Malaysia

Specialization : Strategic Management, Operation & Project Management and
Quality & Change Management.
Current CGPA : 3.64 out of 4.00

20022006

Bachelor of Engineering in Mechanical Engineering (Hons)

Universiti Industri Selangor

CGPA : 3.15 out of 4.00 (2nd Class Upper)
Awards and Honours : Dean’s List for 4 semesters in a row.

19992001

Certificate in Mechanical Engineering

Politeknik Sultan Haji Ahmad Shah (POLISAS)

Able to operate lathe and milling machine under less supervision.
Able to do gas and plasma cut, arc welding, gas welding and brazing

Licenses, Certifications & Training's

• Completed the Training and Passed the Assessments for Integrated Management System (IMS) Standards for (ISO 9001:2015-QMS, ISO 14001:2015-EMS, & OHSAS 18001:2007-SMS) and Integrated Management System (IMS) Process Approach Internal Auditor Training. Training conducted by GT Consultancy (Cert. No. :GT-IMS-2402017-08)
• Attended and passed the Quality Managements System (QMS) Lead Auditor – Transition Course ISO 9001:2008 to ISO 9001:2015. Certificate of Successful Completion, accepted by IRCA for auditor certification. Training conducted by British Standards Institution (BSi) (Cert. No. :ENR-00265469)
• Attended and passed the Quality Managements System (QMS) Lead Auditor - ISO 9001:2008. Certificate of Successful Completion, accepted by IRCA for auditor certification. Training conducted by British Standards Institution (BSi) (Cert. No. :MY09079-03896)
• Certificate of Competence in Storage Technology. Issued by Singapore Polytechnic & IDEMA.
• Certificate in ISO 9001:2000 (QMS) Internal Auditing – Issued by SIRIM Training Services Sdn. Bhd.
• Attended Transition from ISO 9001:2000 to ISO 9001:2008 course.
• Actively involved in QMS & BSI audits - Selected as the Lead Auditor.
• Certificate in ISO 9001:2000 (QMS) Awareness for Competent Application (ACA) – Cert No. QMS060963 Issued by Tradev Research Consultants
• Certificate in ISO 9001:2000 (QMS) Competent Auditing Program (CAP) – Cert No. QMS060974 Issued by Tradev Research Consultants
• Certificate in MS ISO/IEC 17025:2005(LQMS) – Introduction & Understanding
• Certificate in Introductory Training on Liquefied Petroleum Gas (LPG) Safety & Handling (Trained by Panglima Aces Sdn. Bhd)
• Certificate in Applied Project Management (APM) Technology for Effective Teamwork by Applied Thinking Dimension (Malaysia) Sdn. Bhd.
• Certificate in Process Failure Mode & Effects Analysis (Reference AIAG 4th Edition). (Cert No : GT-OE-020317-11)
• Certificate in Statistical Process Improvement (SPI)
• Certificate in Statistical Process Control (SPC)
• Certificate in Measurement Systems Analysis (MSA) using Minitab
• Certificate of Attendance in Ergonomics for Engineers
• Knowledge in Engineering Statistics and Data Analysis
• Knowledge in Design of Experiments Appropriate for Process Improvement
• Knowledge in 8D and 6S tool. Actively implement to improve product quality.
• Registered member of The Institution of Engineering and Technology (IET-UK)
• Registered member of Board of Engineers Malaysia (BEM)(Reg.No: JS53850)
• Registered member of The Institution of Engineers, Malaysia (IEM) (Reg. No:38742)                                     

• Registered member of Malaysia Board of Technologist (MBOT)

Career Development

  • Pursuing Professional Engineer certification under IEM / BEM.
  • Pursuing Project Management Plan (PMP) Certification under Sharma Management International.