Suresh Nair

ADDRESS: *** ****** **** *****, *********, ONTARIO, N2N 3S3

phone: 519-***-**** ( home)

e-mail: ad44kf@r.postjobfree.com

PROFILE

Resulted-oriented Production Manager with a proven track record of implementing lean manufacturing principles,

streaming lining production processes, and improving overall efficiency. Intuitive ability to select and secure top

performers, maintaining open communication with supervisors and production crews to achieve operational objectives and

goals. Production Management with extensive experience in production and operational /process improvement within

Automobile, Electrical/Electronic, Rubber Manufacturing, Hardware, and Medical industries globally.

AREAS OF EXPERTISE

• Production Management of multi shifts • CI -Lean Manufacturing, 6S and cost saving initiative

• Cross-functional communication and people leadership • Budget generation and control

• Inventory Management- raw and finished • Cost reduction and quality programs

• Recruiting, training, coaching, personnel management • Quality Objective and implementation

• Multistage process scheduling • Safety & Health, Environment and Programs

• Analytical Problem Solving • Production planning and scheduling

• ISO 9001/14000 Implementation and Audit • SAP / KRONUS /JD Edward

SIGNIFICANT ACHIEVEMENTS

• Managed plant floor assembly lines (5 lines, 150 operators, multi shift operations)

• Formulated and implemented plans for manpower reduction and quality improvement initiatives.

• Increased production from 75 to 85% through value stream mapping the manufacturing processes and eliminating

non-value processes at Johnsonite

• Assembly Time Reduction at Toyota– tack time study, line balancing, man/machine study, material supply and

automation.

• OEE improvement from 60% to 75~80% within 6 months at G&W ; Johnsonite and RIM

• Evaluated Manufacturing Process & Tooling design; equipment inspection and installation buy off; ensured

operational requirements and functionality, repeatability, cycle time, ergonomics, poke yoke and applicable standards.

• Process Quality – Improved yield by 32% through restructuring production operation processes and training.

• Development and maintaining of Lean Manufacturing concepts in multiple organization

• Directed all aspects of Hitachi plant’s rebuilding process and Turn around the manufacturing plant.

• SAP implementation in Hitachi and North West Rubber.

• Improved Machine Downtime - implemented an effective Predictive and Preventative Maintenance program.

• Manpower reduction by 15% with the introduction of a robotic packing automation system at medical device

manufacturer.

PROFESSIONAL EXPERIENCE

G &W Electric Canada (Brampton) 2020 – present

G&W provides power grid solutions-load and fault interrupting switches, reclosures, system protection equipment,

Power grid automation/transmission and distribution cable terminations, joints, and other cable accessories.

Production Supervisor to Production Manager

Manages the muti shift manufacturing operations and employees for welding, electronic/hardware and assembly sections.

Developing objectives and continuous improvement initiatives in the areas of cost, methods, quality, and quantity of work

performed. Collaborating with personnel from all supporting departments- engineering, maintenance, planning,etc

• Lead and mentor a manufacturing workforce consisting of approximately 57 employees including Supervisor,

Team Leaders and hourly production worker;

• Daily production performance update and departmental monthly strategic meeting

• Lead the designated value stream to meet and improve schedule dates, reduce process times, reduce inventory

levels and increase the utilisation of resources;

• Apply company guidelines, aiming to ensure a healthy and safe working environment by running a safe,

injury/accident-free workplace;

• Evaluate and update the performance of team members against their job requirements and performance goals

within the time frame designated for their position level ;

• Review all accident/incident investigation report and providing recommendations in corrective actions ;

• Workplace inspection and risk assessment of the assigned areas and updating the SDS for new material

introduced to plant

• Recruiting and onboarding of team members and annual performance review of staffs;

• Institute policies and controls for cost-cutting and research new processes and equipment that may improve

throughput and profitability

• Establish and measure manufacturing strategic vision progress through KPI’s

• Responsible for creating business plan budget (capital and expense) and follow up action plan

Significant Accomplishments:

Achieved 100% production attainment for the 3 value stream areas within 6 months

Weld leak reduction from 3% to 0.5% at final assembly within 4 months

Upscaling of production from 8hrs 2 shift to 24 hrs operation

OEE improvement – From 55% to 75% within 5 months through line balancing, proper tools, standardize work and data

analysis.

Johnsonite Inc (Waterloo) 2016 – 2019 (plant closure)

Johnsonite delivers the broadest portfolio of high-performance, resilient flooring surfaces in the flooring industry.

Production Manager

Managed production of extruded wall base and satisfied all safety, quality, delivery, cost, and processing standards.

Overall efficiency and effectiveness of all production operations and production people.

• Member of the plant management in development and implementation of operational policies and procedures and

operational direction of the plant

• Maintained a positive and proactive approach in motivating entire plant team to work to achieve WCM results;

improved people and results when and where necessary ensuring Johnsonite zero incident safety, health, and

environment culture.

• Led, developed, and participated in continuous improvement activities/projects across plant such as Kaizen, 5S +1,

WPO, Gemba walks and value stream mapping events which focused on Quality, Cost, Audits and Delivery.

• Developed team to primarily focus on continuous improvement of safety, quality, costs, production, lead time, flexibility

and customer service.

• Reviewed daily production schedules; monitored production levels and addressed issues that caused off schedule

conditions; strategically planned materials, equipment, and labour.

• Maintained, reviewed, and reported KPIs, plans and variances at daily/weekly review meetings and monthly updates

on improvements and opportunities.

• Worked closely with shift supervisors to implement and manage an effective training program that fostered individual

team member development and skill gaps improvement

• Acted as Pillar leader for the Autonomous Maintenance and member of Project, Cost and Quality Pillars.

Significant Accomplishments:

Production output – Increased the daily OEE - 72% to 88.5% within 2 years- through training, CI and defect analysis.

Safety – 16 years of zero accident and incident

Cost savings – Worked on projects that led to annual saving of $1 million and $1.2 million for 2017 and 2018 respectively.

North West Rubber (Brantford) 2013 – 2016

North West Rubber provides specialty rubber flooring products to retail, commercial and industrial customers for a

variety of applications- agricultural, recreational, playground, traffic safety, trailer, truck bed mat, etc.

Process and Production Supervisor

Supervised, led and coached employees in a manufacturing operation and responsible for safety, hiring, quality and

productivity. Supported the KPIs and CI efforts of the organization to reduce costs.

• Achieved plant corporate goals for safety, quality, productivity and shipment to customer fulfillment.

• Planned and established weekly and monthly labor/machine requirements including work assign to team members

• Implemented manufacturing best practices and work procedure

• Monitored and enforced safe working practices in accordance with company policy legislative requirements and WSIB

documentations and active member of JHSC

• Worked with sales on delivery timing and stock level of different products and lead time improvement

• Coordinated noise and other industrial hygiene testing and activities and maintaining the records

• Identified workplace hazards through work place assessments and improvement plans to reduce hazards

• Monitored time and attendance of team members and approved vacation/time off request

• Completed electrical and mechanical repairs during off shifts.

• Assessed production order based on product categories and customers quality standards.

• Developed comprehensive employee training and development program to promote and document cross training, new

employee training and orientation, and safety awareness.

• Introduced a series of productivity improvement, process reengineering, cost reduction and performance management

programs, improved production output, product quality and customer satisfaction.

Significant Accomplishments:

Production Output – Increased the daily shift output by 15% through training and staff /machine sequencing.

Product Launch - Successfully launched 4 new products from design stage to production within 1 month and

exceeded customers’ expectation.

Thinkpath Engineering (Cambridge) 2012 - 2013

Process and Project Engineer –Consulting to Toyota (Contract)

Developed, planned, managed and implemented various capital projects for safety, quality, and productivity improvements

for the Automotive Assembly areas. Process and machine capability studies for current and product mix.

• Incorporated new methods and processes to improve existing operations and train production personnel.

• Liaised with vendors by developing specifications and participate in design and commissioning of new equipment.

• Ensured complied to all industry standard equipment and transfer technical expertise to production.

• Conducted workflow analysis, time studies and made recommendations for improvement in material handling, robot

programming and plant layout.

Environmental & Power Solutions Inc. (Kitchener) 2010 – 2012

Senior Process Engineer (Contract)

Process and Project Management for the process optimization and upgrade in manufacturing organizations, both union

and non-union.

• Monitored the cleaning of the filtration systems.

• Initiated process improvement and supply chain support for digital security solutions in SIM/ banking card organization

and food industry.

• Introduced CI activities to improve recovery of material, at each stage of the operation.

• Oversaw assembly, warehouse and time management.

• Ensured total validation process; equipment validation, IQ, OQ, PQ and CQ for medical equipment manufacturer.

Ozburn Hessey Logistics (3PL) (Mississauga) 2008 – 2009

Production/Logistic Manager (Contract)

Led and managed personnel in warehouse and consumer packaging (health food and dry foods, chocolate and

confectionary products).

• Built and tailored operational standard and work instructions for total warehouse.

• Interfaced with teammates, vendor representatives and customers to resolve issues relating to product quality, order

fulfillment and delivery schedules.

• Conducted cycle-count, inventory programs based on individual clients, costing, GMP compliance and Food Security.

• Monthly inventory cycle count and adjustment with the clients

Blackberry (formerly Research In Motion) (Waterloo) 2003 – 2008

Process Maintenance Manager • 2007 –2008

Coordinated of all maintenance personnel, systems and assembly equipment (SMT, Testing and Final Assembly) for the

entire production facility. Coordinated Continuous Improvement programs within the organization.

• Prepared budget for capital expansion, staffing requirements and line layouts.

• Conducted individual monthly technician expectation meetings.

• Developed, implemented, and maintained a monthly and annual preventive maintenance program.

• Coordinated spare parts management for all production equipment, assembly fixtures and CMMS compliance

Production Manager /Front Line Manager • 2003 –2007

Production staff- SMT ;assembly, testing and material handlers. Consistently met daily shipping schedules. Liaised with

other supervisors during shift changeover and daily shift and time sheet reports.

• Maximised production and repair through planning, organizing and scheduling production line operations.

• Analyzed facility layout and process flow charts to determine efficient utilization of workers and equipment;

implemented and drove KPIs and lean.

• Investigated product nonconformity related to quality, production, scrap and maintenance throughout the shift.

• Introduced and continuous adhering to best manufacturing practices

• NPI to mass production transition- total of 5 products

Significant Accomplishments:

Production Output – Highest production volume in a shift, in RIM’s history.

Monthly Quality Rate – Lead the crew that produced 3 continuous months of lowest DPP.

EDUCATION & PROFESSIONAL DEVELOPMENT

Graduate Diploma in Industrial Management • Swinburne University of Technology (Melbourne, Australia)

Bachelor’s Degree in mechanical engineering • Swinburne University of Technology (Melbourne, Australia)

• Project Management Fundamentals and Application (University of Waterloo)

• Lean Manufacturing (6S)

• TPM and OEE for Maintenance Managers

• Leadership for Managers

• KPI Implementations and Analysis

• Health and Safety for Managers

• Due Diligence for Managers

• Quality Concepts and Tools in Manufacturing

• ISO 9000/14000/18000

• STOP Implementation

• First –Aid certification

COMPUTER PROGRAMS/SOFTWARE

MS-Project (project management) • MS-Access (database) • Oracle (database) • MS-PowerPoint • MS-Excel • Lotus

Notes • SAP • MS-Word • AutoCAD • Synapse • Minitab • Solidworks

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