Supply Chain Six Sigma

Yogesh K. Makkar

**** ***** ** ** ****** MN *****.

• Phone: Cell 607-***-**** • Email – *******@*****.***

Result oriented, knowledgeable and self-motivated professional with 12+ years of progressive experience

spanning into breadth and depth of operations management. A persuasive leader with hands on experience

involving change management and improvement in sales and operations planning, procurement, inventory

management, customer relations, organization team building, new projects management and six sigma

application. Core expertise include: -

Sales and Operations Planning Inventory Management and Control Budget and cost control

New product Launch Value stream planning Six Sigma application

ERP suites implementation Lean manufacturing practices Supply chain planning

Supplier development Operations, execution, control and improvement

Professional Experience

Cummins Inc. 10/2010 – Till Date

Cummins Inc., a global leader is a corporation of complementary business units, in heavy automotive engines,

automotive products, distribution network, and power solutions for recreational, commercial and marine

applications.

Materials Manager

Lead functions spanning across procurement, sales and operations planning, operations execution and Inventory

management with a team of 16 professionals, consisting of Master Schedulers, Buyers, Planners and Shop Floor

Controller. Providing leadership to 2 largest business segments of business unit to deliver annual revenue

exceeding $725M. Engage cross functional leaders to build short term and long term plan, provide leadership for

functional excellence projects of materials management, inventory control modules and cycle counting and to an

initiative for the exemption from Annual Physical Inventory process. Active sponsor and reviewer of six sigma

projects.

Selected Achievements -

Envisioned, developed and implemented an inventory control model to support highly variable demand of

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“Gensets” in RV / Marine/ Commercial mobile vehicle market. Plan led to inventory classification, optimal

safety stock calculation incorporating seasonality, trend and cost.

Completed six sigma projects leading to redefining the sourcing strategy for raw materials from overseas

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suppliers. Leading to improved flow, elimination of premium freight and inventory reduction.

Sponsored various six sigma projects, leading to Green belt certification, in manufacturing process flow

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improvement, business process flow improvement, improving operations, material flow and transaction on

production lines, to obtain a net savings exceeding $ 1.0 M annually.

Accomplished inventory reduction from $25 M to $18 M over a span of 12 months (a 28% reduction in

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inventory), and maintained challenging 98% on-time delivery to customer.

Leader of functional excellence of cycle counting.

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Led and executed a large project to conduct Annual Physical Inventory (API) for the business unit. Provided

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leadership to a cross functional team of 32 members (logistics, operations, IT, materials management and

Finance) to conduct API for approx 39,000 SKUs, equating $ Value of $90 M+.

Eaton Corporation: 11/2006– 10/2010

Eaton Corporation, a diversified global business corporation, is engaged in the manufacturing of automotive,

electrical, hydraulic and aerospace products.

Master Scheduler and Business Process Consultant (Oracle Manufacturing): 03/2009 – 10/2010

Master Scheduler: 11/2006 – 03/2009

Define and flow map business processes, collaboration with IT team for the implementation of manufacturing

suites under Oracle ERP system. Production planning, operations control and delivery to customer and lead team

(professional and shop floor employees). Customer relation management. Establish Sales Inventory and

Operations Plan (SIOP) process. Liaison with cross functional teams to establish forecast cycles and planning

horizon, establish KPI, data collection and measurement process, implementation of a new forecasting software

tool. Present SIOP to plant leadership team and execute the plan on a monthly basis. Establish annual operating

plan, operating business long term goal and plant metrics performance. Presentation of plant results to executive

leadership team at HQ.

Selected Achievements:–

Led planning, inventory management, material replenishment, production activity control and forecasting for

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the implementation of Oracle ERP manufacturing system. Completed the project for full life cycle

implementation including user testing, training and implement.

By using business process reengineering methods achieved reduction in material outages by working with IT/

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Supply Chain to set up discipline and new reports to be used by buyers.

Implemented a six sigma project (umbrella project) to align resources to improve and sustain the On Time

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Performance (OTP). Implemented the “CONWIP” method of controlling job orders and material control.

Outcome results were increase in OTD from 40% to 85%., lead time reduction by 4 days.

Reduce DOH (Days on Hand) of 15% reduction year after year using continuous improvement initiatives.

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Developed Sales Inventory and Operations Planning (SIOP) process. Conducted plant wide training, metric

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defined and sustained practice year after year.

Lincoln Plating Company: 4/2005 – 10/2006

Lincoln Plating Company is a Tier-1 supplier to Harley-Davidson Motorcycle Company supplying various

components for decorative and functional use in motorcycles.

Supply Chain Project Engineer:

End-to-end supply chain management, develop sales forecasts and financial profit plans, establish production and

delivery schedules, manage purchasing, inventory and cost control, customer relations management .

• Executed six new products launch. Established quality standards, execution of PPAP (Parts Production

Approval Process), establish logistics systems across the supply chain, establish key inventory levels at all

stages (Suppliers, in house, in transit).

• Accomplished and sustained a tough goal of 99% On Time Delivery.

• A key player in a cross functional team for ERP system implementation of supply and production flow

system. Full life cycle implementation including current state analysis, gap identification, mapping,

developing solution, implementation and user training.

Engineering Division, Escorts ltd. -India 4/1995 - 7/2000

Escorts, a multi engineering corporation has a dominant presence in automotive, farm machinery, construction

machinery, and communication and railway products.

Project Manager: 07/1998 – 07/2000

Manager - Operations: 05/1997 – 07/1998

Assistant Manager - Operations: 06/1996 – 05/1997

Manufacturing Engineer / Supervisor: 05/1995 – 06/1996

Plant layout planning, installation and commissioning of machines, deliver a functioning unit to operations team

for regular production. Production process development and time studies, process standardization, capacity and

planning methodology analysis. Continuous improvement initiative, analysis and design of supply chain system.

Build annual operating plans in conjunction with vice president of operation, supervise operations processes and

policies in support of organizations mission.

Selected Achievements

Executed a breakthrough joint venture project between the Escorts Ltd of India and the ICER Ltd of Spain for

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the setting up of a new manufacturing line of Synthetic Brake Blocks. Delivered the project on time in

compliance with the quality standards of the product.

Implemented the ISO 9002 Quality systems at Escorts ltd.

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Supplier development – Mentoring /coaching of suppliers for their ISO 9000 certification compliance in order

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to comply with end customer’s requirements. Functional Consultant for a core vendor of Escorts Ltd., to

implement ISO - 9002 Quality Systems

Active participation in union contracts negotiations.

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Reduced the material flow time of work in process for the brake assembly unit by 25% (from 16 hrs to 12 hrs)

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by leading Business Process Improvement initiatives.

Redesigned the surface treatment lines for ferrous metal products. Scope included process layout design,

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redesign of tooling and machinery and flow channels, vendor selection and process modification. Achieved

outstanding improvements in cost, quality, and process through put reduction time including improving the

safety of operators.

Educational Work Experience:

Graduate Instructor: University of Nebraska Lincoln. 08/2004 – 05/2005

Research Assistant: University of Nebraska Lincoln. 01/2001 – 07/2004

Research interest – Non-traditional Manufacturing processes, Decision Analysis, Environmental Risk Analysis of

manufacturing processes. Applied probability and Statistics.

Selected Accomplishments: -

Under an NSF (National Science Foundation) funded project, innovated a new manufacturing method and

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built (designed, fabricated and assembled the machine) a computerized controlled machine in the Center for

Nontraditional Manufacturing research at UNL to machine micro cavities in metals using ECM. By using a

fine tool as small as 25 µm, we successfully created 3-dimensional shapes with micro precision in stainless

steel metal block.

Education / Professional Certifications:

M.B.A. – Colorado State University In Progress - Expected Completion May -2014.

M. S. - Industrial and Management Systems Engineering, GPA – 3.85. 12/ 2002

University of Nebraska, Lincoln

B. Tech.- Mechanical Engineering (Honors) 05/1996

National Institute of Technology, Kurukshetra (India)

Certifications:

CSCP - Certified Supply Chain Professional through APICS.

CQE - Certified Quality Engineer through ASQ

Six Sigma Green Belt from Eaton Corporation

SAS certified base SAS programmer.

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