M Kesavan Mariapa
gelugor
Summary
Results-driven manager with over 20 years of experience in SMT, HLA, box build, and semiconductor industries. Expertise in NPI, project management, cost reduction, inventory optimisation, continuous improvement, and LEAN methodologies. Holds an Engineering degree in Electrical and Electronics Engineering from University Technology Malaysia, demonstrating a strong foundation in technical and business development skills.
Overview
27
27
years of professional experience
Work History
Process Manger-Electromechanically Operation lead
FLEX
Bukit Minyak, Penang, Malaysia
11.2020 - Current
- Led end-to-end manufacturing operations for complex semiconductor test equipment (Box Build), supporting advanced technologies including Logic, RF, Analog, Power, Mixed-Signal, and Memory platforms, driving manufacturing strategy, new product introduction (NPI), engineering, planning, production, automation, quality, cost optimization, and continuous improvement to achieve world-class operational performance.
- Lead and manage the complete Box Build manufacturing operation, overseeing production, planning, process engineering, equipment engineering, testing, quality, logistics, and resource management to ensure safe, efficient, and on-time product delivery.
- Successfully led three major product transfer programs from Suzhou, China, ensuring seamless technology transfer, manufacturing readiness, workforce capability, documentation compliance, and uninterrupted customer supply.
- Owned complete NPI lifecycle from project kick-off through mass production and sustaining, ensuring alignment of resources and timelines to meet market demands.
- Ensure full manufacturing readiness by driving the 4M + 1E methodology (Man, Machine, Material, Method, Environment), minimising launch risks and ensuring successful product ramp-up.
- Lead a multidisciplinary engineering organization comprising NPI Engineering, Manufacturing Engineering, Process Engineering, Equipment Engineering, Automation Engineering, Product Engineering, and Test Engineering.
- Manage an engineering team representing approximately 40% of the overall organization, aligning technical resources with business priorities and operational objectives.
- Developed and executed comprehensive production strategies encompassing demand forecast planning, capacity planning, and master production scheduling (MPS) to enhance operational efficiency and responsiveness to customer needs.
- Balance customer demand with manufacturing capacity to maximize throughput and delivery performance.
- Drive operational excellence by monitoring key performance indicators (KPIs), including: On-Time Delivery (OTD), Perfect Installation Program (PIP), Productivity, Yield, Cycle Time, Equipment Utilization.
- Implement immediate corrective actions to address production constraints and operational risks.
- Develop real-time operational dashboards to monitor manufacturing performance, enabling data-driven decision making, rapid issue escalation, and proactive management of production performance.
- Establish structured inventory control processes for indirect materials, including TML, RTS, RTV, consumables, and production supplies.
- Improve inventory health while reducing excess stock, shortages, and operational waste.
- Conduct daily operational reviews with customers to align demand forecasts, production schedules, shipment commitments, and Master Production Schedule (MPS).
- Support mixed-platform manufacturing with an average daily output of 10 systems while maintaining delivery commitments.
- Partner with engineering teams to continuously improve: First Pass Success (FPS), First Pass Yield (FPY), Defect Reduction, Process Capability.
- Led root cause analysis and corrective actions to improve manufacturing quality.
- Champion Lean Manufacturing principles through daily 5S implementation, weekly Gemba walks, and continuous safety improvement initiatives to maintain a highly organized, efficient, and accident-free workplace.
- Lead factory automation initiatives by implementing advanced manufacturing tools and automated processes to improve productivity, reduce manual operations, minimize errors, and enhance product quality.
- Manage Factory Operating Loss (FOL) by optimizing: Utility consumption, Indirect Direct Material (IDM), Manufacturing scrap, Rework, Operational waste.
- Drive continuous cost reduction initiatives while maintaining product quality and customer satisfaction.
- Improve direct labor efficiency through process optimization, line balancing, automation, standardized work, and continuous improvement projects.
- Develop structured training, coaching, and cross-functional competency programs to strengthen workforce capability, improve operational flexibility, and prepare future technical leaders.
- Increased manufacturing capacity from 5 systems per week to 45 systems per week, representing an 800% production increase, through process optimization, capacity expansion, automation, and workforce development while maintaining quality and delivery performance.
- Successfully converted approximately 30% of manual manufacturing processes into automated operations, including: Auto Scanning, Auto Foaming, Auto Strapping, Auto Screw Tightening, Automated Inspection Systems.
- Improved manufacturing consistency, reduced cycle time, and increased overall productivity.
- Achieved a 90% reduction in workmanship-related scrap by implementing: Semi-automated robotic handling, Custom protective covers, Ergonomic handling fixtures and jigs, Standardized work instructions.
- Significantly improved product quality while reducing manufacturing costs.
- Increased workforce multi-skilling by 85% through structured cross-training programs, improving manpower flexibility and significantly reducing production downtime caused by employee absences.
- Improved manufacturing operational yield from 70% to 98% by: Implementing electronic production checklists (e-Checklist), Strengthening process controls, Driving root cause analysis, Standardizing work procedures, Monitoring process performance through data-driven continuous improvement initiatives.
Mold Manager - Backend Manager
ASEM
Bayan Lepas, Penang, Malaysia
05.2018 - 11.2020
- Worked as a Back-End Operations Lead in the Flash Memory Technology division, supporting the manufacturing of NAND-based storage products, including USB flash drives, memory cards, Solid-State Drives (SSDs), and High Bandwidth Flash (HBF). Drove operational excellence, process optimization, quality improvement, and production efficiency across multiple manufacturing processes.
- Planned, monitored, and executed production activities for SMT, AOI, Mold, Laser Marking, Trimming, Packaging, Inspection, and Packing operations to ensure on-time delivery and production targets.
- Provided engineering support for new product introduction (NPI) by optimizing process parameters, establishing SMT machine settings, and ensuring a smooth product ramp-up.
- Designed and implemented production layouts and process flow improvements to enhance manufacturing efficiency and optimise cycle time.
- Developed and validated process designs using solid compound and mold chase design, ensuring compliance with product specifications and manufacturing standards.
- Performed quality validation and qualification for new supplier materials and compounds before production implementation.
- Established and optimized DOE (Design of Experiments) for TOWA molding machine parameters to improve product quality, yield, and process stability.
- Led continuous improvement initiatives by troubleshooting production and equipment issues, implementing corrective actions, and driving productivity enhancement projects.
- Monitored daily manufacturing KPIs, analysed operational performance, collaborated with cross-functional teams to identify and implement process improvements that enhanced overall efficiency.
- Conducted production capacity planning and resource allocation to maximize equipment utilization and meet customer demand.
- Supervised daily production operations by coordinating engineering, supervisory, technician, and operator activities to ensure smooth workflow execution.
- Evaluated workforce performance through KPI tracking, coaching, and performance measurement to improve operational effectiveness.
- Managed workplace safety, inventory control, and material handling processes while ensuring compliance with company standards and regulatory requirements.
- Reduced compound scrap losses through improved inventory control, material handling practices, and optimised storage methods, extending material shelf life and minimising waste.
- Led process optimization project reducing MImaki die consumption by approximately 60%, achieving significant manufacturing cost savings and earning recognition from senior management with an internal award for operational excellence.
Process Engineer- Section Head
Plexus Manufacturing
11.2012 - 05.2018
- Led the High-Level Assembly (HLA) and Box Build manufacturing operations for high-end Network Station and Industrial Test Equipment products, ensuring on-time delivery while meeting quality, cost, and productivity targets.
- Managed the assembly of high-complexity systems comprising approximately 6,000 individual components, with a standard build cycle of four days, ensuring manufacturing excellence and customer satisfaction.
- Successfully led the transfer of eight product models from Chicago and San Jose, USA, completing the entire technology transfer program within four months while ensuring a seamless transition into volume production.
- Conducted Design for Manufacturability (DFM) and Design of Experiments (DOE) studies to optimise manufacturing processes, enhance product quality, and mitigate production risks during product transfer.
- Established complete manufacturing documentation, including Process Flow, Control Plan, and Process Failure Mode and Effects Analysis (PFMEA) to ensure robust process control and compliance with quality standards.
- Developed and standardized comprehensive Work Instructions (WI) to improve operator consistency, training effectiveness, and manufacturing quality.
- Created and validated the Bill of Materials (BOM) while collaborating with MRO and Supplier Quality Engineering (SQE) teams to qualify suppliers and ensure material readiness for production.
- Identified Internal Direct Material (IDM) requirements and established inventory planning strategies that ensured uninterrupted production and strengthened material availability.
- Designed and implemented structured training programs for operators, technicians, and engineers to enhance technical competency, process compliance, and overall workforce capability.
- Implemented Smart Torque Systems, advanced manufacturing tools, and Poka-Yoke (Error-Proofing) solutions to improve assembly accuracy, reduce human error, and enhance product quality.
- Designed and developed smart assembly workstations that improved ergonomics, production efficiency, operator productivity, and manufacturing consistency.
- Led continuous improvement initiatives using Lean Kaizen and DMAIC methodologies to optimize manufacturing processes, eliminate waste, improve productivity, and reduce production costs.
- Served as the primary engineering representative for sustaining activities, conducting regular technical review meetings with USA-based customers to address quality concerns, drive continuous improvements, and ensure customer satisfaction.
- Actively contributed as a member of the Safety, Health, and Environment (SHE) committee, supporting workplace safety initiatives, risk assessments, and continuous improvement programs to promote a safe working environment.
- Successfully led the transfer of multiple high-complexity products from the USA to the local manufacturing site, achieving on-time project completion with minimal production issues. Received recognition from both management and customers for outstanding project execution, effective cross-functional coordination, and a smooth production ramp-up.
- Improved production First Pass Yield (FPY) to 98% by identifying sensor breakage during the assembly process. Designed and implemented a specialized assembly jig that eliminated sensor damage, significantly reducing defects, rework, and manufacturing costs while improving product reliability.
- Increased manufacturing productivity by 20% through the design and implementation of a semi-automated robotic handling system for heavy semi-finished assemblies. The solution reduced manual handling, improved operator safety and ergonomics, shortened cycle time, and enhanced overall production efficiency.
- Conducted engineering studies and successfully implemented the use of a gold-plated alignment pin (“Gold Pin”) to resolve press-fit connector contact issues. This improvement enhanced assembly consistency, electrical contact reliability, and long-term product performance while reducing assembly-related defects.
- Developed and mentored multiple operators and technicians through structured cross-training and competency development programs, creating a strong succession pipeline. This ensured operational continuity, improved workforce flexibility, and minimized production risks during manpower shortages and business expansion.
- Championed Lean Manufacturing and continuous improvement initiatives by identifying process bottlenecks and implementing engineering solutions that enhanced productivity, quality, and cost efficiency across manufacturing operations.
Senior Technician-Process Engineer
Sanshin (M) Sdn. Bhd.
Sungai Petani, Kedah, Malaysia
01.2000 - 11.2012
- In charge of manufacturing an Optical Disc Drive (ODD) allows a computer to read and write optical discs such as CDs, DVDs, and Blu-ray discs. It is commonly used for playing media, installing software, and creating backups.
- Monitor and manage assembly and test production line performance by tracking key manufacturing metrics such as output, cycle time, first-pass yield (FPY), downtime, and quality performance. Ensure production targets are achieved while maintaining safety, quality, and delivery commitments.
- Provide shift support for machine and tester downtime, responding immediately to production interruptions. Perform root cause analysis, coordinate with maintenance, equipment, and test engineering teams, implement corrective actions, and restore production with minimum downtime.
- Trained and mentored production operators on new product introduction (NPI), assembly processes, work instructions, quality requirements, and standardised operating procedures, ensuring consistent workmanship and compliance with manufacturing standards.
- Design, develop, and fabricate Poka-Yoke (mistake-proofing) devices and ergonomic fixtures to eliminate operator errors, improve product quality, reduce repetitive motion, enhance workplace safety, and increase overall production efficiency.
- Support New Product Introduction (NPI) implementation by participating in prototype builds, process validation, manufacturing readiness reviews, line setup, process optimization, risk assessments, and successful transfer from engineering to mass production.
- Develop and maintain Control Plans, Standard Operating Procedures (SOP), Work Instructions (WI), visual aids, and quality documentation to ensure standardized manufacturing processes, product quality, and operator compliance.
- Collected, analysed, and interpreted manufacturing data related to yield, defects, downtime, cycle time, and productivity to support continuous improvement initiatives, identifying trends and recommending corrective actions for process optimisation.
- Participated in Process Failure Mode and Effects Analysis (PFMEA), Design of Experiments (DOE), and Gauge Repeatability & Reproducibility (GR&R) studies to identify process risks, optimise manufacturing parameters, validate measurement systems, and enhance process capability.
- Perform advanced troubleshooting of complex PCBA and system assembly issues, utilizing schematic analysis, engineering drawings, diagnostic tools, failure analysis techniques, and cross-functional collaboration to identify and resolve manufacturing and product-related problems.
- Lead troubleshooting and recovery of production machinery and automated test equipment, coordinating with equipment suppliers and engineering teams to minimize downtime, improve equipment reliability, and increase Overall Equipment Effectiveness (OEE).
- Investigate new failure modes and sudden defect spikes using structured problem-solving methodologies such as 8D, 5 Why, Fishbone Diagram, Pareto Analysis, and Root Cause Analysis (RCA). Implement corrective and preventive actions (CAPA) to prevent recurrence and improve product reliability.
- Successfully led the New Product Introduction (NPI) of a 10 mm slim, lightweight Optical Disc Drive (ODD) featuring a high-complexity mechanical assembly, ensuring a smooth product launch and manufacturing readiness.
- Resolved major production quality issues related to Drive IC and QFN failures by performing detailed circuit-level troubleshooting. Designed and implemented a PCBA testing gate to detect defects early, preventing defective assemblies from progressing to the HLA build stage and improving overall product quality.
- Reduced model changeover time from one full shift to one hour by leading a Lean Kaizen improvement project. The initiative significantly improved production flexibility and productivity and was recognized as a Global Winning Project for its operational impact.
- Performed detailed signal noise analysis to identify the root cause of intermittent failures, successfully tracing the issue to internally damaged incoming capacitors. Collaborated with cross-functional teams to implement corrective actions, improving product reliability and reducing recurring defects.
Education
Bachelor's Degree - Electrical and Electronic
University Technology Malaysia
01-2011
Diploma - Electrical/Electronic
College Linton
01-1998
Skills
- Technical expertise
- Project management
- Process optimization
- NPI
- Cost down project
- Continuous improvement
- Lean manufacturing
- Kaizen
- PFMEA
- Root cause analysis
- Inventory control
- Team leadership
- Lean manufacturing
Custom
- Mr. Kelvin Liu, Senior Director of ASE, +6012 4132298, Previous Manager
- Mr. Alex Chan, Senior Manager of Flextronics, +6012 5577738, Previous Manager
Languages
English
Upper Intermediate
B2
Work Availability
monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
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Timeline
Process Manger-Electromechanically Operation lead
FLEX
11.2020 - Current
Mold Manager - Backend Manager
ASEM
05.2018 - 11.2020
Process Engineer- Section Head
Plexus Manufacturing
11.2012 - 05.2018
Senior Technician-Process Engineer
Sanshin (M) Sdn. Bhd.
01.2000 - 11.2012
Bachelor's Degree - Electrical and Electronic
University Technology Malaysia
Diploma - Electrical/Electronic
College Linton