Vijayan Sinnasamy
Director Manufacturing Operations & Technical
Nibong Tebal
Summary
Experienced technical and manufacturing operations leader with a strong background in the petrochemicals and plastics industry. Skilled in establishing and optimizing technical and manufacturing processes, measurement and control systems, and laboratory facilities to drive business performance. Adept at deploying strategic plans and effectively benchmarking performance against key operational targets. Extensive experience in construction, installation, and startup of manufacturing and laboratory infrastructure. Proven track record in application development, process improvement, and quality assurance, including ISO quality and environmental management systems. Well-versed in handling government-related issues related to environment, safety, and import permits. Recognized for expertise in industry and government sector liaison functions. Active participation in industry sectorial committees such as the Malaysian Petrochemicals Association (MPA), Plastic Resins Producers Group (PRPG), and Skills Advisory Committee under the National Vocational Training Council. Served as an industry representative on the Government-headed Technical Committee on Chemical Weapons Convention implementation. A versatile Technical Director with 33 years of experience in assessing challenges, resolving problems, and implementing effective plans to mitigate risk and overcome technical obstacles.
Overview
35
35
years of professional experience
1985
1985
years of post-secondary education
12
12
Certifications
3
3
Languages
Work History
Manufacturing & TECHNICAL Director
KINMON (GUANGDONG) PLASTIC TECHNOLOGY
09.2022 - Current
- Company Overview: Manufacturer of compounded engineering plastic resins
- Reporting directly to the CEO
- Member of the Board of Directors
- Maintained standards during factory construction, production line layouts, established production staff requirements, production documentation requirements, prepared inputs for cost feasibility study and QA requirements
- Preparing processing requirements and plans for machine configuration capability tests at manufacturers
- Manage production of products including BOM issuance and related systems
- Lead Technology Transfer and New Product Development
- Direct QA system and customer technical service
- Direct plant and equipment maintenance
- Manufacturer of compounded engineering plastic resins
Factory Manager/Production Management Director
UNICORN INDUSTRY (M) SDN BHD
08.2018 - 08.2022
- Company Overview: Manufacturer of recycled and compounded plastic resins
- Reporting directly to the Managing Director
- Lead manufacturing operations with 65 employees covering materials processing, production, maintenance, QA and warehouse departments
- Established system for processing post-consumer and post-industry plastics off-grades
- Achieved new OEM customers including product formulation development, application development and defining quality requirements
- Ensured factory machinery and procedures for compounding and recycling manufacturing and compliance to product and business requirements from customers
- Achieved compliances to safety and environmental legal requirements and liaise with relevant government departments to resolve compliance issues
- Resolved Customs and other government issues and compliances for importation of materials – AP, Customs Ruling, Basel Convention
- Developed statistically determined product portfolio covering ABS, Glass reinforced ABS and SAN, PC, PC/ABS, HIPS, GPPS, PP and others
- Manufacturer of recycled and compounded plastic resins
General Manager, Manufacturing Operations
TEXCHEM POLYMERS SDN BHD
12.2014 - 06.2018
- Company Overview: Leading manufacturer of biomass plastic resins and plastic sheets
- Reporting directly to the Managing Director
- Lead manufacturing operations with 40 employees covering production, maintenance, and liaise with HR, QA, Finance and Supply Chain Management
- Achieved improved operations for increased gross profit margins by 5 - 20% out from the red
- Achieved Production yield improvements from 86% to 98%- and lower-unit electricity consumption reduction by 17 – 40%
- Achieved improvements to inventory management reducing year end stock count variances to below 2% down from 10-20%
- Oversee operations interface with R&D and sales/marketing to coordinate development and execution of production processes for 16 developmental products
- Lead execution of new investment projects for manufacturing line upgrading that contributed 20 – 25% increase in top line sales
- Achieved plans for future investment project infrastructure
- Leading manufacturer of biomass plastic resins and plastic sheets
Senior Manager I, Quality Assurance
TEXCHEM-PACK (PP) SDN BHD
01.2014 - 11.2014
- Company Overview: Manufacturer of plastic moulded parts for semiconductor and E&E industries and medical devices
- Concurrent Assistant to DMD (Feb 2014 ~ Nov 2014)
- Reporting directly to the Deputy Managing Director who is leading plant operations
- Manage 10 QA staff and acted as assistant to DMD
- Oversight of product quality and issuance of FA reports for new projects
- Acted as Quality Management Representative (QMR) and as Environmental Management Representative (EMR)
- Provided stewardship for Quality Management System (QMS) and Environmental Management System (EMS) and ensure implementation in accordance to the requirements
- Resolved two HDD customer audits and resolved quality issue affecting Sales of major wafer shipper product
- Manufacturer of plastic moulded parts for semiconductor and E&E industries and medical devices
Head of Plant Optimization Natural Polymers & Rubber
SYNTHOMER SDN. BHD.
02.2013 - 06.2013
- Company Overview: Major supplier of lattices and specialty emulsion polymers with leadership positions in many market segments including coatings, construction, textiles, paper and synthetic latex gloves
- Head of Process Improvement, Asia (Dec 2011 ~ Jan 2013)
- Reporting directly to the Operations Director and Site Manager leading plant optimization
- Oversee process improvements of 3 plants regionally
- Achieved three projects related to construction and improvements in effluent and waste water reduction and treatment costing MYR 6 million in addition to process improvements
- Managed energy management collaborative study with university and alternatives study with consulting partners
- Managed Management of Change (MoC) system and facilitated changes
- Achieved successful revival of waste water treatment facility for natural rubber and dispersion plants that would have resulted in plant shutdowns by eliminating ammoniacal nitrogen discharge and lowering COD
- Successfully completed safety enhancement activities highlighted by global SHE team
- Major supplier of lattices and specialty emulsion polymers with leadership positions in many market segments including coatings, construction, textiles, paper and synthetic latex gloves
Head, Polymer Technology & Development
ENTEGRIS (MALAYSIA) SDN. BHD.
07.2008 - 11.2011
- Company Overview: A global leader creating material advantages for customers in wafer, semiconductor and electronics industry
- Senior Materials Research Scientist (Jul 2006 ~ Jun 2008)
- Reporting directly to the Materials Manager at Chaska (MN, USA) and Materials Characterisation director
- Leading inhouse polymer R&D, manufacturing and purification in addition to materials engineering
- Managed recycling manufacturing activities related to company global EOL parts harvest system
- Achieved strategic new materials R&D activities and developed cost effective formulations with direct and potential savings of up to US$ 2 million annually in material costs
- Managed site materials engineering activities reporting to group Materials Engineering Manager at US
- Managed planning and execution of new manufacturing infrastructure project and ASTM compliant laboratory for polymer tests
- Acted as Lean Sigma Manufacturing Champion and completed Green Belt kaizen project
- A global leader creating material advantages for customers in wafer, semiconductor and electronics industry
Technology Centre Manager
TORAY PLASTICS (MALAYSIA) SDN. BHD.
10.2005 - 06.2006
- Company Overview: Largest manufacturer of ABS plastics resins in S.E
- Asia export markets worldwide
- Technical Department Manager (Oct 1996 ~ Sept 2005)
- QA Section Head (Apr 1991 ~ Sept 1996)
- Reporting directly to the Managing Director leading Technology Centre and technical functions encompassing R&D, application development and process improvement in addition to quality assurance, product liability and industry liaison affairs
- Managed 26 staffs including expatriates at Technology Centre including laboratory and testing facilities internally and externally including procurement of equipment and lab design
- Achieved R&D, process improvement and application development projects resulting in introduction of 15 new products since 1993 resulting in more than USD 65 Million profits
- Achieved successful coordination and implementation of process improvement, application development and field customer service functions supporting sales turnover of more than USD 300 million/year globally which includes quality assurance function for 220,000 metric tons of ABS per year and equivalent quantity of raw materials at main plants and sub-contractors
- Achieved successful completion of technical feasibility studies for debottlenecking project worth over USD 8 million
- Successfully lead Technical aspects for 4 expansion projects involving capacity increases and pre-start-up sales ramping activities
- Successfully managed company ISO 9000 QMS obtaining certification independently
- Advisor for ISO 14000 EMS system
- Facilitated product certifications for mandatory and customer requirements including RoHS, CWC, and others
- Managed company product liability system including coordinating review of critical risk applications of company products and resolved potential product liability cases
- Participated as Management team for company safety-health-environment committee, budget/expense meetings and production cost control meetings
- Represented management at industry groups, namely MPA/PRPG Exco, MITI/MIDA Dialogues, and MPMA Dialogues and organized and presented at public seminars and conferences since 1994
- Participated in expert / advisory roles appointed by government agencies and institutions of higher learning
- Successfully improved tender procedures with increased recovery of scrap revenue by more than 75%
- Largest manufacturer of ABS plastics resins in S.E
- Asia export markets worldwide
Research Officer
NATIONAL DRUG RESEARCH CENTRE, UNIVERSITI SAINS MALAYSIA.
01.1990 - 01.1991
- Company Overview: R&D organization on tropical drugs (medicine) and narcotics drug research
- Supported by grants from major drug companies, UN and Government
- Research Assistant (1985 ~ 1989)
- Reporting to the Director leading in research studies on tropical medicines and narcotics
- Development of analytical and chromatographic methods for analysis of drugs and metabolites in body fluids and assist in clinical trials
- Assisted in various clinical trials on new anti-malarial and anti-filarial drugs from global drug companies in affiliation with WHO (UN)
- Training of lab technicians and general lab administration
- R&D organization on tropical drugs (medicine) and narcotics drug research
- Supported by grants from major drug companies, UN and Government
Education
Bachelors of Science, Hons. - Chemistry
Universiti Sains Malaysia
Masters of Science - Analytical Chemistry
Universiti Sains Malaysia
Skills
Plastics Production Installation Knowledge
Certification
Understanding and Documenting a Quality Management System, Neville Clarke, 1991
Affiliations
Associate, Malaysian Institute of Chemistry, A/1087/2086/90, Toastmaster, Kulim Toastmasters Club, Malaysian Petrochemicals Association (MPA), Council member, 1994 ~ 2006, Plastic Resins Producers Group (PRPG), EXCO, 1994 ~ 2006, International Malaysia-Japan Plastics Conference (IMJPC), Organizing Committee, 2002, 2004, 2006, Asia Petrochemicals Industry Conference (APIC), Council committee, 2004
Personal Information
- Number of Children: 3
- Date of Birth: 06/20/61
- Gender: Male
Accomplishments
- Collaborated with team of [Number] in the development of [Project name].
- Resolved product issue through consumer testing.
- Achieved [Result] through effectively helping with [Task].
- Supervised team of [Number] staff members.
- Documented and resolved [Issue] which led to [Results].
Affiliations
- Toastmasters
Timeline
Manufacturing & TECHNICAL Director
KINMON (GUANGDONG) PLASTIC TECHNOLOGY
09.2022 - Current
Factory Manager/Production Management Director
UNICORN INDUSTRY (M) SDN BHD
08.2018 - 08.2022
General Manager, Manufacturing Operations
TEXCHEM POLYMERS SDN BHD
12.2014 - 06.2018
Senior Manager I, Quality Assurance
TEXCHEM-PACK (PP) SDN BHD
01.2014 - 11.2014
Head of Plant Optimization Natural Polymers & Rubber
SYNTHOMER SDN. BHD.
02.2013 - 06.2013
Head, Polymer Technology & Development
ENTEGRIS (MALAYSIA) SDN. BHD.
07.2008 - 11.2011
Technology Centre Manager
TORAY PLASTICS (MALAYSIA) SDN. BHD.
10.2005 - 06.2006
Research Officer
NATIONAL DRUG RESEARCH CENTRE, UNIVERSITI SAINS MALAYSIA.
01.1990 - 01.1991
Masters of Science - Analytical Chemistry
Universiti Sains Malaysia
Bachelors of Science, Hons. - Chemistry
Universiti Sains Malaysia
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