Sanjay S Kuppusamy

Same role being carried out as in Inforce Computing Inc. for EMS Operations Management after acquisition and with additional role of Production Manager at SMART Modular Technologies EMBEDDED Product Line.

• Lead Group of Manufacturing Superintendent/Supervisors for Embedded Product operations and responsible to oversee manufacturing process of products and direct activities in ensuring products are manufactured On Timely manner and within Quality Standards and Cost
• Maintained professional, organized, and safe environment for employees and patrons.
• Put people first methodology by Establishing Programs & Activities for Employees in ensuring sustainable workforce and minimize attrition rate
• Create versatile workforce program, establish programs and activities for employees in ensuring manufacturing flexibility and stability with staffs trained and certified for more than 1 process which lead to minimum attrition rate

Accomplishments:-

• Managed and delivered revenue increase from $6 mils to $10 mils at EMS factories in Malaysia, Taiwan and USA for Wireless Product and revenue increase from $8 mils to $15 mils at SMART Embedded Product line on quarterly basis over last 4 years
• Achieved SMT Utilization averaging at 75% by ensuring liner line loading, involving with Engineering Team on Industry 4.0 implementations on Auto Loader & Unloader
• Exceeded work orders closure within 14 days averaging at 98% against target 95%
• Internal PDD maintained averaging at 92% against target 80%
• Final QA holding DPPM achieved at 100 DPPM versus target of 500 DPPM
• Overall operations cost well maintained below than given budget
• Direct Labor attrition rate well maintained below 2% attrition rate by focusing on Consistent and Predictable Operations for Workforce Stability
• Completion of 10 Kaizen/LEAN Projects by team under direct supervision which contributed in Productivity, Quality, Cost, Delivery, Safety and Morale improvements
• Lead Wireless product transfer from Taiwan EMS Factory to SMART Embedded Penang smoothly, passed all samples and line qualifications build, customer audit, certification audits and released for mass production within targeted timeline.

Inforce Computing Inc. being acquired by SMART Modular Technologies in July 2019.

• Manage EMS in Malaysia, Taiwan and USA from prototyping design to mass production release
• Worked smoothly with internal and external customers in time-sensitive environment
• Identify and anticipate issues, bottlenecks and problem areas in order to mitigate schedule and deliverable risks
• Develop detailed factory materials plan for consign ad turn key as well as complete product delivery schedule of all PROTO, NPI and production orders and closely monitor execution of plan
• Maximize performance by monitoring EMS factories daily activities and mentoring team members in delivering quality products on time with competitive cost to end customers worldwide
• Obtain quote responses in timely manner and negotiate pricing details to meet given cost target

Accomplishments:-

• Managed and delivered revenue increase from $10k to $5 mils quarter over quarter at EMS factories in Malaysia, Taiwan and USA for Wireless Product in 7 years of services
• Wireless project startup coordination between hardware design team in Cochin India, software Development team in Bangalore India and EMS factories in Malaysia, Taiwan and USA and materials team for consign items located in Malaysia & India
• EMS factories readiness review, build readiness review, line audits and qualifications
• Coordinated with external certifications body such as UL, DEMKO, CCC for factory inspection activities and achieved 0 NC
• Lead and host for end customer visits and audits. Hosted CAVIUM NETWORKS, MARVELL, RMG, CRESTRONE, MIRROR, INVIXIUM, VIDEON, SOFTBANK ROBOTICS, SIGHTLINE, and successfully passed audits and visits with positive inputs from customers
• Completed total of 110 variants BOM Setup and Software Package Transfer to EMS factories
• PROTO, NPI, PILOT and Mass Production Build coordination and execution involving Hardware and Software Design Team in India to EMS factories in Malaysia, Taiwan and USA
• Drive for operational KPIs, indicators being improved and maintained for Internal OTD-97%, External OTD-100%, Final Yield – 98%, QA LAR – 99%
• Coordinated overall packaging items development, validations, qualifications and go live activities with EMS Engineering, Materials Team and Packaging Suppliers
• Improved web orders shipment TAT from averaging 5-7 days to 1-2 days upon receiving online orders and payment by implementing finished goods racking with online view of stocks by model and variants
• Inventory count accuracy for consign items improved from 75% to 99.5% by implementing one to one exchange of high value components and implementing kit to exact process.

• Manage and lead group of Supervisors, Technicians, Leader's & Operators to ensure on time delivery with built in quality for CISCO Direct Fulfillment Chassis orders
• Plan and organize available equipment, materials and manpower to meet production Schedules and direct flow of work to ensure it is in accordance to plan and recommend appropriate Changes for improvements
• Collect and analyze information on daily, weekly and monthly basis and make recommendation to superior and other relevant department on yield, quality, wastage reduction, productivity and efficiency improvements

Accomplishments:-

• Direct fulfillment OTD improved from 85% to 95% by implementing real time system monitoring during testing and buzzer triggering at Burn Cell for failed units to be attended immediately and fixed
• Chassis assembly cycle time improvement from 35 minutes to 15 minutes per unit for full configuration chassis by doing line re-layout for 1 piece flow methodology
• Implementation of automated conveyor system with in-line automated strapping process to eliminate safety hazard, improve cycle time from 12 minutes to 5 minutes per chassis packing and reduced headcount from 3 person to 2 person per shift.

• Manufacturing operations Lead for Flash Product SMT, Back end, IC Stacking and SSD product start-up
• Lead team of Supervisors, Leaders, Operators and support team. Plan and organize availability of equipment, materials and manpower in achieving department's and company's goal and target through optimum utilization of available resources and with minimum cost to ship quality products on time
• Production key representative for Customers and TUV certification body audits

Accomplishments:-

• OTD to end customers consistently maintained at averaging at 99%
• QC headcount reduction project from 10 per shift to 4 per shift by implementing sampling inspection at Back end contributed by SPI, AOI and moving manual soldering components to SMT mount
• Lead plant wide Visual Management System standardization for signage, work stations, waste bins and implementation of on-line output, yield and defect triggering systems
• Reduction in WIP processing time from 10 days to 5 days at assembly line contributed by implementation of Branson process automation, reduction in equipment set-up and conversion time, product level BOM change from 2 level to 1 level and test racking system
• Increase PC Base Test throughput by 60% with zero headcount increase by implementing test racking system. Headcount manning improved from to 1 operator to 8 slots compared to 1 operator to 2 slot and reduction in OT cost
• Ultrasound welding process automation completed for 8 machines contributed to 40% increase in UPH and elimination of non-value-added activities
• IBM MRR audit success, lead for back end assembly line. Redesign and set-up overall back end assembly line, ergonomic friendly work stations, implemented on-line ESD monitoring at work stations and designed new concept of ESD safe product for storage and transportation.

• Administer, coordinate and conduct systematic training for Trainers and Certifiers and ensure of necessary skills and knowledge availability to train and certify operators to assemble, inspect and test Hard Disc Drive and Head stacks
• Work closely with NPI Team in developing process of new training skills and processes as required for new products

Accomplishments:-

• Completed training, certification and release to production for total of 1,000 operators in duration of 4 months in line with ramp up plan
• Implemented On-line certification check system which contributed in elimination of certification badge holders, cards, stickers and paper usage. Cost saving of RM125k yearly achieved
• Implemented fixed wrist at all stations in clean room which eliminated individual wrist strap issuance. Reduction of new wrist strap issuance by 2,800 units on quarterly basis and cost saving of RM189k achieved
• Implemented MITEC scanning system for all clean room work stations which was linked Training Database. Elimination of uncertified operators performing job and this has improved overall quality and Back end DPPM improved from 2,500 DPPM to 1,000 DPPM.

• Manufacturing Head Stack product startup project lead
• Plan, manage and ensure line readiness, equipment, materials and manpower availability based on targeted ramp up plan

Accomplishment:-

• Lead and accomplished 30 Head Stack assembly cells qualification and release to production in duration of 3 months
• Improvement on outgoing DPPM at Final VMI station from 5,500 DPPM to 200 DPPM for Shunt Wire defects by suggesting and implementing Vacuum Shunt Pen to pick HGAs during assembly process which eliminates damages occurred by human force during pick up using tweezers
• Improvement on outgoing DPPM at Final VMI station from 7,700 DPPM to 180 DPPM for Missing Epoxy defects by suggesting and implementing Auto Epoxy Dispenser which eliminate operator judgement and dependency
• Productivity improvement for 2 Platters Head Stacks by implementing conveyor system from 1st till final process at assembly cell which eliminates operators to hand over completed units from each station by hand and waiting time. Output increased by 500 units per shift per cell from 1,200 units to 1,700 units
• Headcount reduction from 6 to 5 operators per assembly cell by combining 2 of shortest time taken processes into 1. Eliminated waiting time and total headcount reduced was 90 operators across 3 shifts for 30 assembly cells

• Back end Slider Vendor Cell department Coordinator. Lead group of Leaders and Operators in achieving day to day operations goals and target
• Responsible for headcount manning based on loading plan and deliver products with highest quality standards

Accomplishments:-

• Outstanding performance award for 5 times
• Completed 6 QCC Projects as Team Leader and became Champion for 6 consecutive quarters with total project savings of RM1.4 mils
• Won Best Speaker Award for all 6 QCC Project presentation events
• Represent company as Team Leader in NPC Regional QCC Convention in year 1998 - Silver Award and year 2000 - Gold Award
• Represent company as Team Leader in NPC National QCC Convention in year 2000 and won Gold 3 Star Award and achieved Top 10 in Electronic Industries category.