Mathew Panicker Eappen Email & Phone Number

Norwich, England, United Kingdom

• Collaborated with design engineering to comprehend paint material testing standards required by product specifications and developed a comprehensive new colour development procedure in collaboration with the paint supplier.• Implemented and executed an annual plan to control and monitor the curing condition of 13 baking ovens in alignment with the specified paint TDS requirements.• Developed detailed process documentation for in-house painting of previously outsourced parts, ensuring comprehensive understanding and seamless integration of the new painting process.• Co-ordinate with production to conduct improvement trials for new handle jigs, skid frame covers, oven settings for line speed-up, and process changes in the part preparation area, contributing to ongoing operational enhancements.• Formulating a business case for investing in paint resistivity testing and spectrophotometry equipment to boost quality control and reduce costs.

Bengaluru, Karnataka, India

• Advocated making current production lines flexible between Scooters and motorcycles to meet fluctuating market demand in one-fourth of the initial budget plan. (£4.8 million). • Collaborated closely with Honda Japan's R&D on a specification change in a low-cost new product launch that resulted in an annual cost reduction of £83,000 by lean manufacturing.• Responsible for Paint's incoming quality control catering to 2.4 million vehicles per year, by ensuring 100% inspection of incoming material and finished parts by achieving 99% assurance.• Managed paint-shop operations that cater capacity of 1.8 million vehicles per year leading a team of 10 engineers and 248 workers.• Implemented CKD parts special secondary inspection process, ensuring rigorous quality checks and achieving 100% defect-free assurance before final supply to packing.• Performed strategic planning, process improvement, quality control, budget management, risk management, performance monitoring and KPIs reporting.

Bengaluru, Karnataka, India

• Achieved benchmark KPI across Global Honda plants by continuous improvement, with an Overall Equipment efficiency of 89% and a straight pass ratio of 98% in metal and 94% in plastic lines.• Certified Risk Assessor in OSHMS and contribute to the identification, assessment, and management of risks in the workplace.• Collaborated as a vital member of the “Global Bukai Team” in Honda Asia Oceania region, fostering global synergy by implementing standardized processes and facilitating the exchange of cutting-edge technological insights for benchmark targets and results.• Managed the operations of a greenfield paint shop (4 Lines) with a capacity of 0.6 million vehicles per year leading a team of 10 engineers and 280 workers• Coordinated manpower planning and training of new personnel.

Bengaluru, Karnataka, India

• Executed and manage the full life cycle of a paint shop expansion project with a production capacity of 0.6 million vehicles per year and an investment of £17 million for a new product launch.• Performed capacity planning, process planning, layout planning, budgeting, value engineering, project monitoring, installation, and commissioning. • Reduced capital investment by £2 million and maximised capacity flexibility through process commonization.• Developed technological innovation, "Auto booth balancing system," that enhanced painting efficiency and boost straight pass by 2%.• Won Second place for innovation at the Honda Technical Meet in India and proposed to be implemented across Honda’s global factories.

Bengaluru, Karnataka, India

• Managed operations of a paint shop (2 lines) catering for a capacity of 1.8 million vehicles per year with a team of 10 engineers and 220 workers.• Led successful start-up of a new greenfield paint manufacturing facility and execute six sigma projects to achieve full operational efficiency of 95%.• Responsible for Preparing & controlling the budget for Paint cost, Consumable cost, capital investments etc..• Responsible for overall defect reduction & continual improvement in Production with Quality.• Responsible for directing overall production targets and achievements.

Bangalore

• Selected as team member for my paint shop expertise in the Greenfield plant expansion project to achieve target of 1.8 million vehicles/year.• Performed installation and commissioning for 10 new painting lines.• Worked hand in hand with 5 Japanese consultants and 5 Indian engineers.• Monitored schedule, budget & compliance to standards on a regular basis.• Liaised with external equipment makers for smooth project progress and maintenance.• Conducted trials in painting line and quality confirmation of the products according to HES ( Honda Engineering Standards)• Designed jigs and fixtures needed for new painting line.• Trained new line personnel theoretically and hands on job training as per process requirements.• Implemented a comprehensive Quality Control Plan (QCP), and SOPs for consistent operations, integrated SPC methods in PT and ED processes, and enhanced stability.• Implemented Gauge R&R and Measurement System Analysis (MSA) techniques to evaluate and enhance the reliability of measurement systems used in quality inspections.

Gurgaon, India

• Managed operations of a paint shop (1 line) catering for a capacity of 0.4 million vehicles per year and supervised the process engineering activities.• 18% Increase in productivity by increasing part density in a painting envelope without reducing output quality and additionally improving painting efficiency by 2%.• Define the inspection criteria and process for higher-end CBU model exported to Europe with a daily production of 40 per day and train a separate inspection team to achieve defect-free parts.• Responsible for production planning, manpower planning of above line as per production volume target.• Ensured control over paint consumption and improvement of painting quality.• Introduced to Painting techniques like Electro static Gun, Bell Painting & 2K resin mixing equipment.• Responsible for achieving monthly Business targets & reporting results to Top management.• Developed new jigs , fixtures & masking for new Vehicle models.

Gurgaon, India

• Production responsibility of Metal Paint Line• Designed and implemented new procedures and systems to achieve certification for Global Honda Quality standards (Quality Management System) in India• Root cause Analysis & critical defect presentations on monthly basis to the manufacturing Head & Quality Vice-president• Monitoring paint shop process parameters• Ensuring the QAV’s as per plan of outsourced parts (Process verification & part Quality).• Coordinating ISO: 9001(internal & external), internal QAV & 5S audits.• Led the re-inspection team for painted parts of export models and CKD parts.

Gurgaon, India

• Supervised the operations of the two-wheeler body component paint shop and performed process engineering activities• Maintaining `5S' in Lines of production and look out for best procedures for shift production standards, cost reduction, etc.• Perform continuous improvement in shop floor to Production, Quality, Ergonomics etc. by Kaizens and PDCA• Planning & Co-ordinating all new models on line.

Master Of Business Administration - Mba

Master Of Business Administration - Mba (Summer Exchange), Supply Chain And Sustainability

B.Tech, Mechaical