Responsibilities/Accomplishments:

Responsible for leading the company initiative to move towards lean production environment. Acting as a central resource for lean manufacturing and assisting with day-to-day production support and improvements
Initiating investigations against customer complaints. Collaborating with sales personnel, engineering, manufacturing and quality assurance to find root cause of the problem and taking corrective actions
Tracking and evaluation of key manufacturing/quality metrics (5S implementation, inventory control, process yield, machine downtime, reportable health and safety incidents) and recommending GSTD (Go, See, Think, Do) initiatives for continuous improvement in manufacturing lines
Implementation of KPI’s for various manufacturing departments to help measure managing daily improvement (MDI)
Analysis of workforce utilization, facility layout, and operation data, such as production flow charts, statistical analysis, flow path analysis and production schedules to determine efficient utilization of workers and equipment

Responsibilities/Accomplishments:

Proactively managed production operations for plastic auto parts and FMCG-packaging using latest IML technology. Prepared production reports, quality reports and other documentation including SOP’s, machine loading, resource forecasting, quality assurance, worker training, machine maintenance, safety and environmental standards
Spearheaded machine installation, commissioning and start-up of production machine lines and ensured production stabilization after installation
Customer complaint handling and management. Conducted RCA and resolved recurring NCR’s by taking CAPAs with the plant team
Supervised and designed systems that ensured end to end quality starting from incoming quality checks to in process quality checks and then finished goods quality checks
Led visual management activities, implemented Kaizen(s), Poka Yoke methodologies and conducted monthly performance review sessions to develop KPI's for whole team

Major Achievements:

Led QCC(Quality Control Circles) on site and initiated quality improvement projects. Worked as a facilitator on 7 QC tools, 5S, Kaizen(s), Poka Yoke, Process Capability, Heijunka, Jidoka, JIT and Kanban
Managed production operations with focus on TPM/WCM & 5S that reduced machine downtime and waste of motion looking for tools, information & materials that increased production and reduced per unit cost
Conducted time and motion study at assembly line to identify bottleneck processes and eliminate human error. Installed two robots on assembly line and reduced human error from 3% to 0% and assembly time by 27%
Delivered orders on time and with best quality to achieve client satisfaction, build rapport and client’s trust that helped get more orders. Well managed inventory helped deliver urgent orders on time and received remarks

Responsibilities/Accomplishments:

Responsibly managed production operations for FMCG plastic products; prepared and provided information for manufacturing decision-making by calculating production, labor and material costs; reviewed production schedules and estimated future requirements
Assured product and process quality by designing testing methods; tested finished product and process capabilities; established standards. Oversaw installation, operation, maintenance and repair of machinery to ensure that machines and equipment are installed and functioning according to specifications

Major Achievements:

Studied production process to identify critical processes; highlighted worker capabilities and conducted shuffling to increase production from 102,000 units to 135,000 units weekly
Trained workers for strict quality control and quality assurance methods to meet quality standards of Unilever products and achieved remarks
Proactively contributed to reduce human error in the labeling process; reduced human error, in some cases, by 10% to 15%