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Summary
Results-driven, skilled Head of operations focused on achieving success and increased productivity. Spearheads rapid improvements in operations. Proponent of hands-on implementation of quality, safety and administration improvements via organizational updates. Well-versed in training, equipping and motivating team members to optimize productivity and efficiency. Proponent of human-centric approach to expanding production effectiveness and efficiency. Highly confident in turning around production lines with an analytical and well-coordinated approach.
Skills
Master scheduling
Planned equipment constraints
Workforce training
Knowledgeable of quality control standards
Knowledge of 8D problem solving process
Quality assurance controls
Maintenance planning
Toyota Production System
Optimizing production output
Safety management
Experience
07/2019 to CurrentHead of Operations-Assembly and Injection MoldingKerry | Mount Prospect, IL,
Contributed to all production design activities through delivery of specific components, spanning quote and contract proposals, technical requirements, financial planning and staffing. Model Y, 3, Rivian Flush ODH,etc.
Simplified complex specifications into logical design requirements for production during new project reviews.
Diligently maintained safety and quality standards on the production line.
Evaluated current production processes and made forward-thinking adjustments to improve output on the Ford Bronco, Escape assembly line thus reducing Head count requirement for the line by 50%.
Set schedules and allocated resources for current and backlog production requirements.
Discussed product value and vision with team members while encouraging new ideas and suggestions with meetings established at the "Gemba" taking a leaf out of TPS (Toyota Production System).
Liaised between senior plant management and line-level supervision to maintain open communications and solve problems quickly.
Transformed work area by increasing production, reducing turnover, eliminating waste and enhancing quality by implementing Lean Principles.
Implemented root cause and corrective actions to remove production constraints and improve product quality by 55% over a period of a year.
Produced daily operations report, including forecasting staffing needs and production volume, to support cost-reduction and service improvement initiatives.
Budgeted monthly departmental expenses and implemented cost controls.
Implemented Lean Six Sigma and 5S methodologies to achieve highly productive workflow in an organized environment thereby increasing efficiency by 35% at the Cadillac Assembly line.
Monitored KPIs and implemented localized assembly line reviews to increase performance.
10/2016 to 07/2019Plastics Injection Molding ManagerElementis | New Martinsville, WV,
Managed 24 Injection Molding machines on a 3 shift operation with Directing and motivating 12 direct reporting team and 55 indirect reporting team of production staff.
Reviewed production orders, schedules, delivery dates and inventory levels to determine product availability.
Adjusted daily work procedures to meet schedules and improved product quality by 97% in the molding department over a course of a year.
Monitored staff activities to meet compliance, productivity and revenue goals.
Created and implemented cost controls and other expense reduction measures.
Achieved on-budget performance and production targets through effective management of process engineering teams and production resources.
Coordinated preventive maintenance on existing and new production equipment, including routine calibration thus leading to a stable molding process parameters for all job's in the plastics department.
Defined manufacturing performance standards and reviewed performance outcomes to set future targets.
Evaluated quality of materials and products to meet total quality management standards.
Manage and plan equipment transfers with optimization of layouts to increase workflow efficiency.
Liaise with the Quality Department to communicate product or quality issues and provide technical and process solutions to resolve these issues.
Established SMED standard for effective and fast mold changes thus increasing efficiency of mold changes by 87%.
05/2016 to 09/2016Process Improvement ManagerHuf North America | City, STATE,
Compiled, modeled and reported on paint plants essential indicators and factors and KPI data to support reducing Scrap by 45%.
Identified exceptions and deviations and recommended corrective actions to realign processes to all manufacturing Departmental Managers.
Developed the Quality dashboard with all the KPI’s required for the successful monitoring of live quality levels across all departments in the plant with comparisons to customer quality requirements.
Helped develop a structured process for the weekly preventive maintenance procedure for the paint plant with the establishment of a SOP to meet the high quality cleaning and maintenance standards of the paint plant that helped reduce scrap by 10% contributed by Inclusions.
Developed the idea to apply capability calculations for capturing film thickness information in the paint lab to determine trends and establish correlations between paint batches, different primer types, base coat, etc.
Used analytical methods to help in increasing the polishing effectiveness of the reworked painted parts by 25% for all customers.
Led and supervised the lean six sigma project to increase the capability of the ford gas injected handles in the molding department thus reducing workforce requirement by 85% for the Ford Escape molding job.
05/2015 to 12/2015Process Improvement EngineerHuf North America | City, STATE,
Crafted manufacturing processes that were not only robust, but also easy to perform.
Implemented automated visual inspection system for viewing products in the paint shop based on physical dimensions and geometry, speeding up product inspection process by 15% and the quality of inspection by 60%.
Helped run process improvement projects for all departments of the organization for improved work and better utilization of space and equipment’s through the manufacturing plant.
Served as technical resource to initiate and improve processes related to preventative maintenance of machines in the Injection molding department.
Directed cross-functional teams focused on supplier integration with technological strategies in order to enhance global procurement and materials management efficiency thus saving close to 1.8 Million USD per year.
Coordinated with the various department managers to ensure proper workflow through the manufacturing plant creating standardized forklift routes saving 15% of Material handling workforce.
Helped assist Process Engineers in the Molding department to establish process parameters for new tools with the aid of DOE.
Gained hands on experience in the molding department to set molds on IMMs and trouble shoot processes with process technicians.
Education and Training
Expected in 05/2015Master of Science | Industrial EngineeringUniversity of Pittsburgh, Pittsburgh, PAGPA:
Expected in 05/2014Bachelor of Science | Mechanical EngineeringAnna University, Chennai, India, GPA:
Accomplishments
Contributed to an annual 12% increase in productivity through improvements in operations combining assembly and molding operations reducing multiple NVA material handling and improving workforce requirement.
Supervised three shift operations and more than 350 production and assembly line staff.
Saved $300,000 every year by implementing SMED and reducing setup times by 80% for mold changes and thus fred up capacity of IMM by 25% leading to not having to invest on a new IMM for the next budgeted CY saving 1.4 Million USD.
Saved $180,000 every year by implementing one piece flow methodology and reducing operator requirements for an assembly cell by 50% on the Ford Bronco assembly line.
Eliminated the entire rework crew of 6 production associates ($240,000 saving/year) in the molding department by implementing "stop and fix" methodologyand new tool acceptance process with zero rework needed.
Certifications
Lean Six sigma green belt
Lean six sigma black belt
Advanced Plastics injection molding certificate.
Infinity QS process capability and analysis certificate.
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