Vijayram Letcheminasamy

Directed overall plant operations covering production, tooling, maintenance, and assembly functions, ensuring EBITDA and P&L targets were achieved consistently year over year. Implemented operational restructuring and manpower optimization, resulting in a 30% reduction in overhead costs and improved production flow efficiency. Expanded production capability from 18 to 52 machines within a month by optimizing existing assets, reassigning resources, and improving output capacity by over 40%. Led cross-functional coordination between design, engineering, and quality teams to resolve tooling and molding challenges, reducing product rejection rates by 25%. Spearheaded tooling improvement initiatives, including repair and modification programs that extended tool life cycles and reduced downtime. Established preventive maintenance and performance tracking systems, enabling early fault detection and minimizing unplanned machine breakdowns. Fostered a high-performance work culture by coaching team leaders, implementing accountability reviews, and driving continuous improvement mindset across departments.

Oversaw all tooling operations including design approvals, fabrication, and maintenance, ensuring 100% delivery compliance with customer specifications. Enhanced productivity by 20% by implementing standardized tool maintenance checklists and preventive planning systems. Resolved critical customer tooling complaints through root cause analysis and design adjustments, resulting in zero repeat issues. Controlled departmental budgets effectively by realigning labor and materials, contributing to cost savings across the production unit. Collaborated with vendors and design teams to accelerate tooling design cycles and improve manufacturability of complex molds.

Led vendor coordination and tooling validation for multiple product lines, ensuring full compliance with mechanical and dimensional standards. Negotiated pricing and sourcing strategies, achieving annual tooling cost savings exceeding 15%. Improved production efficiency by redesigning tool structures, reducing cycle time and improving throughput. Audited and approved vendors based on process capability and quality system performance to strengthen supplier base reliability. Promoted from Senior Engineer to Staff Engineer (Mar 2012) for exemplary leadership in cost optimization and engineering process improvements.

Supervised tooling operations and engineering teams, ensuring on-time delivery of molds and components to meet strict production schedules. Coordinated tooling projects with overseas vendors (China), overseeing design reviews, tool buy-off, and new factory setup to expand regional capabilities. Enhanced tool quality and lifespan by implementing process improvements and design upgrades that reduced rework and defects by 20%.

Managed mold design and fabrication projects, ensuring customer specifications and quality requirements were fully achieved. Collaborated closely with clients for design approvals and modifications to ensure production readiness and defect-free parts. Optimized tooling manufacturing timelines through effective vendor coordination, achieving faster delivery without compromising accuracy.

Conducted process studies and improvement trials to enhance precision machining and reduce production time per mold. Designed jigs and fixtures for precision components, improving machining consistency and cutting setup errors by 15%. Supported mold base manufacturing and ensured compliance with DME hot runner system standards.

Oversaw daily machining workflow and job routing, optimizing process efficiency and minimizing idle machine hours. Developed process sheets and time estimates for each mold stage, improving planning accuracy and on-time completion. Recommended process improvements that successfully reduced machining time and increased throughput.

Built new plastic and die-cast molds while performing repairs to restore production-ready condition with zero downtime. Provided design feedback to engineers, improving mold manufacturability and reducing fitting errors during trials. Handled multiple concurrent mold projects (5–6 molds) while maintaining high precision and consistent cycle times.

Operated CNC EDM and Wire EDM machines to fabricate precision parts within tight tolerances and quality standards. Maintained high equipment reliability through preventive maintenance and tooling checks. Supported the development of complex molds, contributing to the company’s transition to higher-precision machining standards.

Trained in milling, grinding, and lathe operations, developing solid technical foundations in mold and die making. Assisted senior machinists in tool fabrication, gaining exposure to full machining cycles from roughing to finishing. Demonstrated consistent accuracy and discipline, earning early recognition for precision workmanship.