Venkatesan Elumalai
Chennai,TN
Summary
Dynamic and energetic leader offering over 21 years of cross functional experience; partners with all levels to steer the organization’s culture in support of the organization’s operational and strategic goals and objectives.
Overview
21
21
years of professional experience
1
1
Certification
Work History
Product Application Specialist
Caterpillar India Private Limited
04.2021 - Current
- Provided product and application expertise to the APD regional and dealer sales rep teams to support OHT sales execution, price realization and improved value proposition
- Developed and delivered product, application and operator techniques training to field sales reps, dealers & customers.
- Supported equipment sizing and application recommendations to assist in reduced O&O costs and improved machine performance based on production requirements, job conditions and operator evaluation of OHT's.
- Conducted on-site Performance studies and Provide reports on competitive performance studies, feature/benefit comparisons.
- Trained regional and dealer sales reps. in the use of Value Selling Tool (VST) and other equipment analysis software, and assessed VST input data for critical deals
- Support NPI Development: Provideed input (VOC, VOD, Unmet customer needs, CCR) to Product Groups and NPI teams for next generation NPI /APU product development activities, and engage in NPI for marketing deliverables. (marketing documents)
- Support definition and value placed on new product features, functional and technical specifications and general product requirements.
- Responsible for OHT PINS growth for the region. and evaluate and implement the required programs.
Senior Training Consultant
Caterpillar India Pvt. Ltd
08.2017 - 03.2021
- Talent & Competency development for ICS division
- Design, develop and deliver Technical trainings on caterpillar products and Machine systems through classroom and on-the-job training (Proving grounds, Customer sites, and at factory)
- Delivered Technical trainings on 16+ Caterpillar Product families (OHT, LMT,LWL, Hex, LTTT, Motor Graders, ADT, Wheel dozers, Pavers, Soil compactors, Underground Loaders & Trucks, HMS, SSL, BHL , Hydraulics & Powertrain) on Product key design / selling features, Machine components & systems functions and Its applications.
- Customized Training programs for specific projects which has 100% hands-on product Experience at the field / Workshop. (D&A –Planetary Transmission, Technical Analysis – OHT’s, Product Experience- Next Gen Hex, BHL & SSL- Proving grounds, Pavers & Soil compactors- at customer site)
- Identified resources & Facilitated In-house developed training, vendor provided and custom developed sessions
- Evaluated training programs and self-competency to meet changing demands of the work environment.
- Achieved 92% training session effectiveness through learners feedback consistently as part of learning reaction on trainer’s knowledge, courseware materials, Job impact & Business impact
- Balanced the training programs with Hands-on practical sessions up to 50%.
Section Manager – OHT (Assembly & Test)
Caterpillar India Pvt. Ltd
04.2015 - 07.2017
- Responsible for Off-Highway Trucks (40T,50T,60T,100T) Assembly Unit, handled 2-line managers and 60+ operators including full time and agency employees.
- Implementation of ‘Built in Safety’ and ‘Built in Quality’ concept, Responsible and plan for making Zero incident facility and Zero-defect assembly culture by continuous improvement (CI).
- Production Planning- Daily, Monthly, Quarterly, on People, Quality, Velocity and Cost metrics.
- Identified training needs and provided 8+ trainings to improve competency of the team.
- Continuous improvement by identifying the necessary process changes to make lean production.
- Responsible for CAV & CAV-e audits to meet standards in assembly process. Coordinated with CIPL leadership team to audit the OHT Assembly line on CAV & CAV-e’s.
- Initiated Pre-shift Inspection to give utmost focus on Safety, implemented for the first time in facility, and to fix the issues by closely working with Manufacturing Engineering.
- Raised 178 process change requests (PCR) to fix the issues at source as part of continuous improvement to improve on People, Quality, Velocity and Cost on OHT’s
- Lead 2 Six sigma Green Belt project and 1 RIW to improve from the current state on VSM
- Achieved drastic reduction of DPU from 140+ on Pilot OHT Products to 8 DPU and continuing towards 0 defects in in New NPI’s Off highway trucks through RIW’s
- Built and shipped 19 New NPI machines which was critical for customer order in just 14 shifts by effective Pre-production planning and received recognition from leaders.
Quality Supervisor – Mfg. Quality (OHT, LWL, Hex)
Caterpillar India Pvt. Ltd
12.2010 - 03.2015
- Responsible for Off-highway trucks (40T,50T,60T,100T), LWL (988H), Hex (320D2) Manufacturing Quality. Handled 12 Quality engineers including full time and agency employees.
- Acquired 6 Sigma Greenbelt certificate by CAT University with the projects value approx. of $100K within a year.
- Implementation Lead for BIQ process in OHT assembly line for the first time in the facility as part of Lean initiative.
- Controlled the quality defects throughout machine build from Start-on-line (SOL) to RTS (Ready to ship) to achieve defect free machines by Built in quality process. (8 DPU to 83% defect free machines at Road test)
- Root Cause Analysis of Line, PDI Quality issues & Field reliability issues using Q.C. Tools and taking Interim & Permanent corrective action (RCCA) through CPI tool & Manage facility CPI issues as part of CPI delegate.
- Receive customer feedback through VOC on CIPL build population and take RCCA’s to fix the issues.
- Represented in Titan & Optimus NPI projects / Gateway reviews to fix line quality issues at Pilot stage, (770G,772G,773E,777E) to streamline into assembly process, and fixed 28-line issues before pre-production.
- Lead 3 RIW Projects and 4 GB led sigma projects and have participated in 19 RIW’s & 6 Sigma projects to improve People safety, Quality, Velocity issues.
- Critical RIW / 6 Sigma projects are ‘Reducing cycle time in Quality inspection, ‘Hose fouling defects reduction’, ‘Leak defects reduction, & ‘OHT Steering hard’ issues to reduce rework hrs. & cost
- Implemented Web based application (AQE- All Quality Events) to record Live line Quality gate and PDI defects.
- Played key role in establishing Prime product operator training, followed with operating license for safe work environment in OHT factory.
Manager – Workshop Operations (Underground Gold mine)
Midroc Gold Mine PLC, Ethiopia
03.2009 - 10.2010
- Responsible for 2 UG machine workshop operations and handled 2 supervisors and 32+ technicians.
- Responsible for service & Maintenance management of Caterpillar, Sandvik, Atlas Copco, and Normet Utility Machineries, CAT ADT - 725, Dozers- D9R, Sandvik’s Loaders Toro 7 & 9, Dumpers Toro 50, Rigs Axera 7 & Atlas Copco’s Loader ST1030, Dumper 436B & Rig simba. Normet’s (charging & scaling, Concrete spary) machines.
- Planning scheduled maintenance and yearly budgeting of shop supplies and Spares.
- Providing technical support for issue resolution to ensure smooth operation by eliminating repeated faults / repairs & Sustaining the safe working standards.
- Revalidated the mine slope conditions with mine operations team for improved machine component life.
- Consumed US $ 250000 spare parts from dead stock and Rehabilitated two major breakdown Underground loader machines and two million worth of spare parts from dead stock and Commissioned low availability machines.
- Implemented four shift system to improve employee’s health conditions.
Senior Service Engineer – Product Support (MBG)
GMMCO Limited (CAT Dealer)
09.2004 - 02.2009
- Handled 6+ Service engineers to manage warranty & Non-warranty machines to meet machines availability.
- Caterpillar Machines commissioning and warranty management (Regular & MARC’s)
- Efficiently achieved 85% Warranty machine availability for 25 Nos. 100T Dump trucks & 94% for 992G LWL and D11R TTT’s under Maintenance and Repair Contract (MARC)
- Non-warranty machine maintenance management for 8 + Caterpillar products with a fleet of 70+ machines. OHT (777D / 785C), LWL (992G), LTTT (D11R), Motor Grader (16H), Wheel Dozers’ (834B), MHex (320) & BHL (424)
- Fixing machine issues through root cause analysis using CAT troubleshooting methods (ET, SIS, AFA).
- Support customers on haul road assessment, Best practices, Testing and adjusting, Disassembly and assembly, Parts planning, Operation and maintenance, Tool operating and Contamination control for CAT machines uptime.
- Machine health condition monitoring and customer feedback through Technical analysis (TA) Audits.
- Perform Product Improvement programs (PIP) / Product support programs (PSP) programs as per schedule, TA-1 & TA-2 Analysis as required.
- Received appreciation from HQ for resolving Electrical defect of OHT (777D) machine for Caterpillar India - Tiruvallur manufacturing unit, which was very critical to meet committed shipment date.
- Lead Rectification Program for 777D truck replacement tires, which saved $1.1M for 6 Nos. 777D products and generated service revenue for $800000
- Warranty cost saving $1.1M of 100T Dump truck replacement tires, with TPMS -TKPH analysis report and educated customers on mine layout (Haul road distance) impacting the tire life and improved the tire life drastically.
- Implemented overhauling of Major components of 16H Motor grader (Countershaft transmission) by training the customer assembly team thereby generated service revenue of $2500000
- Executed 10+ PIP / PSP programs for warranty and non-warranty CAT machines.
- Delivered 10+ trainings on OHT Application, Operation & Maintenance practices to customers (Maintenance Managers & Technicians) at customer training centers.
Education
MBA - Marketing management
Madras University
Chennai06-2019
MTech - Manufacturing Management
BITS, Pilani
India04-2015
B.S. - Engineering & Technology
BITS, Pilani
04-2013
Diploma - Mechanical Engg.
S.R.M. Polytechnic College
Chennai04-2004
Skills
- Product support
- Problem solving
- Maintenance and repair practices
- Cross-functional teamwork
- Continuous Improvement
- Machine application
- Worksite safety management
- Effective communication
- 6 sigma
- RCCA (Root cause and corrective action)
- Spare parts inventory management
- Value selling analysis (TCO/CPT/CPH)
- Data analysis
- Lean manufacturing
- People management
- Six sigma
Accomplishments
- Key strengths include working across multiple functions (Product support, Fleet Maintenance & repair, Manufacturing Quality, Manufacturing assembly line, Training and development, Marketing, Application) and cultural backgrounds (India, US, China, Ethiopia & SEA and Aus/NZ countries).
- Recognized for successful completion of pricelist continuous improvement project for all Off-highway truck models and got recognized by division Director & senior VP.
- Implemented Fuel guarantee program for the first time for CAT Off-highway trucks for Indonesia market to improve PINS.
- Conducted 5+ Off-Highway Truck performance / production studies at site for value selling.
- Developed and delivered 29+ product and application training / Value selling / Operating techniques trainings /workshops for CAT dealers and customers in APD region covering 410+ attendees.
- 7 Performance studies conducted at site with different competitive equipments / bodies for value selling analysis. (TCO, CPT)
- Various mine site assessment done at customer sites for optimum target payload for improved TCO/CPT
Certification
- Certified Lean six sigma Black belt
- Acquired CAT 6 Sigma Greenbelt Certificate.
- Certified Hex Specialist -Hydraulic excavator Applications
- Caterpillar Production System (CPS) – Assembler & Paint curriculum
- Acquired DNV –QMS Internal auditor.
- Recognized for OHT pricelist CI project by division director and senior VP.
- Recognition for parts salvage RIW at MRC, which saved $20K
- Recognition for Resolving a critical electrical defect on a 100T truck at the CIPL factory through remote support as a dealer service engineer.
- Project Singham – Critical cost saving project
- Best Employee of the Month – Facility level
- First prize in Quality quiz competition – Facility level
Languages
English
Tamil
Hindi
Telugu (Read, Write & Speak)
Timeline
Product Application Specialist
Caterpillar India Private Limited
04.2021 - Current
Senior Training Consultant
Caterpillar India Pvt. Ltd
08.2017 - 03.2021
Section Manager – OHT (Assembly & Test)
Caterpillar India Pvt. Ltd
04.2015 - 07.2017
Quality Supervisor – Mfg. Quality (OHT, LWL, Hex)
Caterpillar India Pvt. Ltd
12.2010 - 03.2015
Manager – Workshop Operations (Underground Gold mine)
Midroc Gold Mine PLC, Ethiopia
03.2009 - 10.2010
Senior Service Engineer – Product Support (MBG)
GMMCO Limited (CAT Dealer)
09.2004 - 02.2009
MBA - Marketing management
Madras University
MTech - Manufacturing Management
BITS, Pilani
B.S. - Engineering & Technology
BITS, Pilani
Diploma - Mechanical Engg.
S.R.M. Polytechnic College
Career – At a Glance
Professionally matured Graduate mechanical engineer with career success in steering entire Product support, Product application, marketing, value selling, Mines workshop operations, Product Manufacturing Quality, Manufacturing operations and Training & Development with prestigious business organization through technical and leadership skills. Strong credentials in Caterpillar Machine systems and applications at site operations and Built in Quality initiatives to meet defect free machines at Manufacturing operations. Effective team leader, trainer and motivator with fine-tuned analytical and troubleshooting skills.
Personal details
- Date of Birth: 25th July 1985
- Marital status: Married
- Passport No: S0831380