VIJAY RAMASUBRAMANIAN 1150 E 10th Street, Apt A-12 Phone: cell - 803-795-3025 office - 6 15-597-3650 Cookeville, TN-38501 vijay.ramasubramanian@federalmogul.

com vr11934f4@westpost.net

PROFESSIONAL SUMMARY Over 4 years of Professional Continuous Improvement and Manufacturing Engineerin g experience in Tier-1 and Aftermarket Auto-parts manufacturing working towards instilling a Lean culture from the Plant Management level to the Operator level. Profound knowledge and Strong experience in practicing Lean Manufacturing in Ma nufacturing Process Improvement, Operations, Scheduling, Materials, Managing flo w and transactional processes. Proven results in improving KPI and cost savings. GOALS FOR 2011 - Establish a Continuous Improvement Culture by support launch the practice of F MPS in our plant. - Establish a culture of Shop floor Kaizen by teaching and supporting Operators, and Team Leaders with the use of Standardized Work and 8 Step problem solving, to help make their jobs easier. - Master Toyota Values of Team Work, Genchi Genbutsu (Go to the source to find t he facts to make correct decisions, built consensus and achieve goals at our bes t speed) and Kaizen (relentless pursuit for perfection, many minor victories lea d to great success). - Complete MBA and Green Belt with flying colours in the year 2011. ACADEMIC PROFILE * Master of Business Administration, Starti ng Aug 2010 - Expected Graduation Dec 2011 * Six Sigma - Green Belt Expected Completion May 2011 University of Tennessee, Knoxville, TN * Master of Science in Manufacturing Systems Engineering, May 2006 GPA: 3.9 University of Kentucky, Lexington, KY * Bachelor of Engineering in Production Engineering, GPA: 3.4 Madras University, India * Lean Systems Certificate, Lean and Six Sigma training Lean Systems Group, University of Kentucky, Lexington, KY PROFESSIONAL EXPERIENCE Interim Manufacturing Supervisor, Federal-Mogul Corporation, Friction Products, Smithville, TN Nov-Dec 2010 * Supervised/Lead a team of 100 Team Members and 5 Team Leaders over a large man ufacturing Value Stream which included Grinding, Paint and Assembly processes, w orked towards teaching the Core TPS values. * Responsible for maintaining and improving shift KPI's for Safety, 5S, Quality, Delivery, and Productivity. * Lead 8 Step problem solving method with shop floor team members on defects and May 2004

July 2005

rework. * Established Federal-Mogul Production System for the Value Stream, which compri ses of a system for shop floor daily work management and systemic approach for T otal Employee Involvement and Continuous Improvement. Lean Systems Coordinator/Manufacturing Engineer, Federal-Mogul Corporation, Fric tion Product Smithville, TN June-2009-Current * Project Lead for the Redesign of the Plant Information Flow. Designed Order La unch Boards. Created a Hybrid Pull production system in a high variety environme nt. Worked closely with SAP team, Scheduling, tooling and Value Stream teams to identify and implement changes. Before - Delivery Performance - 60 %, After - 90 % * Responsible for Facilitating Kaizen Events and Lead Implementation of action i tems o Facilitated Hands-on Continuous Improvement Events which focused on Value Stre am Mapping, TPS, 5 S, Standardized Work and Problem Solving o Lead Implementation of Kaizens and tracked progress using the Toyota A3 Manage ment process * As a key team member of the Re-layout team, created the Layout for material fl ow, and assisted in identifying ROI for the project. Created Project Plans. Calc ulated Optimal Equipment base and manning based on Takt time and OEE. Cost Savin gs - > $ 1 M * Lead the launch of 8 new assembly based on product families and established va rious lean practices such as 5S, single-piece flow, source quality inspection, S tandardized work, Jidoka - Andon Systems, Autonomous Maintenance, Pacemaker boar d, cell Kanban levels, SMED, trained team members in all the above tools. Cost s avings > $1 M. * Worked closely with production team, maintenance and Machine Builders to ident ify and fix problems and improvements suggestions in the new assembly and packag ing cells. OEE Prior state - 55 % Current 65 -70%. * Lead a team of operators and team leaders on a mission to achieve Single minut e Changeover in the assembly process - Before - C/O - 3 minutes, After - 1.5 min utes Lean Manufacturing Engineer, Federal-Mogul Corporation, Sealing Systems, Summert on, SC, July-2006-June 2009 * Responsible for leading process improvement projects o Improved Standard Work for several processes through Line Balancing and single piece flow. Achieved Productivity Savings of >$1.5 million. o Strongly contributed to a lean transformation to the molding department. Impro ved 30 % improvement in Pieces per labor hour in the molding department. Improve d throughput by workstation improvement, improved Utilization by improving parts shortages and setup time, and implemented a roving quality inspection process t o improve acceptance. o Practiced the SMED concept and reduced Setup time to processes like Stamping, Molding and Assembly. o Established a 6S program, trained, and improved efficiency and space utilizati on. o Lead Plant Layout initiatives and implemented several action items, thereby re ducing material handling o Lead a Lean Maintenance program and conducted analysis to identify critical eq uipment, established an operator PM program, thereby reducing maintenance hours. o Improved material handling and reduced WIP by establishing a Water Spider Rout e o Lead Process Problem solving and eliminated customer rejects due to distortion

and tears in Oil Seals, by implementing Source Inspection, One Piece Flow part handling. Utilized tools like 5 Whys and C&E diagram * Responsible for implementing Lean practices in Operations Management Systems o Implemented a Level Schedule for processes, improved OTD to a 100% and reduced OT. o Calculated Capacity and implemented dedicated parts/machines thereby reduced m achines by 15%. o Established Kanban and FIFO systems for several processes thereby reduced lead time and part shortages. * Manage the Kanban systems by right-sizing Kanban levels. * Responsible for implementing Lean practices in Materials Management o Implemented Supplier Kanban Systems for purchased materials and components o Involved Suppliers in extended Enterprise Value Stream Mapping Activity thereb y reduced lead time by 20%. o Improved flow through reduction in lead time, variability and reducing Lot Siz es. * Manager, Projects -Interim, Federal-Mogul Corporation, India May 2007-Sep 2007 o Supervised a team of civil contractors to design and construct an office space with a capacity of 20. o Identified equipment manufacturers for Capital Equipment, assessed capability, communicated expectations, specifications and requested for quote. o Worked with a cross functional team to develop a project plan to build a new m anufacturing plant in a duration of 1 year and create a Gantt chart. o Developed a Plant Layout for the new plant and ensured layout met lean flow id eals Lean Manufacturing Engineer Intern, SPX Filtran, Lugoff, SC Marc h-2006-July 2006 * Lead two Value Stream Mapping Events, implemented process improvement kaizens. * Implemented Supplier Kanban for purchased components. Created a Plan for Every Part Matrix. * Implemented Point of Use Storage for components thereby reduced material handl ing. ACADEMIC INDUSTRY PROJECTS * Masters Project, Semicon Associates, Lexington, KY - Applied Production Flow A nalysis and Ranked Order Clustering method in a high mix low volume environment to identify product families and machine groups, based on process routings and c apacity. Proposed cell structure and created a plant layout based on findings. I mplemented results in once product family, and validated results. Software Used: Minitab and Excel * Manufacturing Seminar and Project, Trane, Lexington, KY - Used Simulation mode ling software to improve flow of door frame fabrication. Simulation results prov ed 20 % increase in throughput. Software Used: ProModel * Lean Manufacturing Boot Camp 1, 2 and 3, University of Kentucky - Extensive Ha nds-on training on Lean Tools. Lead teams in applying lean tools in simulated te am projects. * Learned application of lean practices through learning plants tours to TMMK, F ord, CLA, CMC and Trim Masters * Six Sigma for Lean Systems - Training on DMAIC process of problems solving. Ap plied Measurement System Analysis, Design of Experiments, in simulated lab envir onment such as the Catapult exercise. Software Used: Minitab COMPUTER SKILLS * Database: MS Access, Packages: MS Office (Excel, PowerPoint, Word), MS Visio, MS Project and AutoCAD.

* Statistical Quality Control: Minitab, JMP