Karthikeyan Karunanithi

Managed complete lifecycle of injection molding projects from RFQ to SOP (Start of Production) Coordinated with design, tooling, production, and quality teams to ensure timely execution Monitored project timelines, cost, and risks using structured planning methods Led trial runs (T0, T1, T2) and ensured smooth PPAP submission and approval Handled engineering changes (ECN) and customer-specific requirements Ensured compliance with quality standards (ISO, customer specs)Identified new business opportunities in automotive / industrial sectors Prepared and submitted RFQs, costing, and feasibility analysis Developed strong customer relationships and handled technical discussions Negotiated pricing, delivery timelines, and commercial terms Supported revenue growth and customer acquisition strategies

Managing injection molding operations and maintaining the manufacturing facility. Coordinate with the Operational Excellence, SCM, BD, and Finance teams to align the unit and company goals/KPIs with their needs. Be responsible for managing the cost, quality, and delivery of designing, building, and developing tooling related to the injection molding process. Lead projects and actions that result in improved quality, process stability, and reduced costs. Act as a liaison between internal departments, including but not limited to Quality, Molding, Project Engineering, Shipping, and Scheduling. Have knowledge of plastic resins, such as poly carbonate, PPE, PS, PEI, PPSU, POM, ABS, PA, and co-polyesters

Manufacture, repair, and provide preventative maintenance and machining for all injection molds. Optimize productivity, improve quality, reduce scrap, and lower operating costs through continual processes. Work with molding vendors to execute innovative ideas and develop productivity. Conduct design reviews for new tool fabrication and provide extended support where needed to strengthen the process. Reduce cycle time and bring cost savings of a minimum 5% per year. Prepare a mold maintenance budget and ensure mold history and performance data are tracked. Provide technical leadership and mentorship to process technicians, operators, and other molding personnel. Work with equipment and material vendors to resolve machine and material issues. Monitor and report issues with injection molds, and make recommendations for refurbishment based on production factors such as cycles, process capability, and tooling history.

Conduct tooling contract review, mold design review, mold trial review, and project review meetings. Provide timely updates and Gantt charts to BD. Attend mold testing and perform molding process optimization to achieve consistent part quality. Study FA reports for dimensional rectification according to product form and fit functions as required by the customer. Lead the team in problem-solving, including identification of problems and analysis of the root cause. Supervise and coordinate with the tool room repair personnel during maintenance and repair. Lead suppliers in tooling troubleshooting and optimization for dimension and visual defects. . Manage projects, ensuring all tooling is executed smoothly and efficiently against an agreed-upon plan. Evaluate plastic injection mold performance. Lead tooling-related activities that include being a subject matter expert during component DFM with clients.. Tool design, tool adjustment, and assisting with root cause analysis of tools under development or in production

Ensuring the delivery of plastic components on time from the subcontractor to avoid line stoppage. Follow up with local tooling suppliers to ensure sufficient mold spares and child parts. Track tooling accessories/spares and conduct monthly inventory. Follow up day-to-day and visit molding vendors to ensure productivity and tooling functions. Evaluate the molding vendor's ability and factory 5S. Follow up with vendors for tool corrections and engineering changes. Strive to achieve zero flash and act decisively regarding the tool, following a 3D tool CAD review.

Managed tool repair, modification, and supplier coordination Reviewed tool design and implemented improvements

Maintained breakdown and preventive maintenance of plastic molds. Followed the mold history card, mold unloading report, and check sheet daily. Conducted mold modifications and function tests. Was on duty for the implementation of tool sub inserts. Followed up on mold spare parts with suppliers. Handled shifts to solve breakdown issues. Independently addressed mold issues. Coordinated with production/process personnel to solve online visual defects. Operated conventional machines to fabricate minor pins, plates, and bushes for molds. Assisted production personnel with tool setting and processes. Handled EOT sorting and standardized the mold for easy access. Applied painting, tags, and names to the tools. Assisted with all utilities and machinery repair/maintenance. Recorded the tooling condition in order on a checklist.

Plastic Mold maintenance, Making, Processing, Molding Production and Design