Plant Management

DESAI

215-***-**** abmopc@r.postjobfree.com

. Business Process Analysis (Production, Inventory, SCM)

. "AS IS" & "TO BE" Systems study

. GAP Analysis, ROI Analysis, SWOT Analysis, Cost Benefit Analysis

. JAD Session, Design SOA, CMMI

. Documentation (FRS, SRS, BRD), Case Analysis and diagram, Activity

Diagrams, Sequence Diagrams, Fishbone Diagram, DFD, ERD, Logic Flow

Diagrams, High Level Design Specifications, Test case generation & Impact

Analysis

. Code testing (Unit testing, Module testing & Integration testing and UAT)

. Inventory Management (Bin, Replenishment, VMI, Safety stock and

Procurement)

. Production Planning, Material Requirement Planning (I,II, III)

. Distribution Requirement Planning & Demand Forecasting

. Supply Chain Management (Inbound, Outbound, Logistics, SCOR, 3PL, Network

Design)

. Warehouse Management

. Operations Management

. Product Development & Life Cycle

. Lean Manufacturing & continuous Improvement

. Project Management, Marketing & Sales Promotion

. Strong Mathematical, Analytical, Lateral Thinking Skills

* Understanding of INCOTERMS 2008

Software Packages: MS Project 2000, MS Office, MS Visio, Visual Basic 6.0,

Oracle Forms 6i, Toad 7.6

DBMS: Oracle 10g/9i/8i, MS Access

PROFESSIONAL EXPERIENCE

Cummins, Rocky Mount NC

July 2007 - Present

http://www.cummins.com

Sr. Analyst (VMI)

Cummins Inc., a global power leader, is a corporation of complementary

business units that design, manufacture, distribute and service engines and

related technologies, including fuel systems, controls, air handling,

filtration, emission solutions and electrical power generation systems.

Responsibilities:

* Perform detailed inventory study and production capacity. Analyze safety

stock, lead time, replenishment quantity per order and supplier.

* Prepare the process flow of the TO BE VMI system and to integrate it with

current production system

* Define safety stock for each any every item and set a reorder point in

VMI system.

* Streamline accounts payable and reducing paper work and number of

invoice. Set up a standard once a month invoicing process.

* Inventory replenishment of actually used items, this avoids storage of

unnecessary items.

* Re defines BOM and upgrade in VMI system for accurate backflush and

eliminating raw material wastage.

* Prepare the process flow diagram and sequence diagram for new VMI system

* Reduce third party job order work and increase quality of product

* Keep track of full delivery or partial delivery for orders

Achieved:

* Reduce Inventory from 8M to 1.6M and inventory holding cost by 60%.

* Eliminate stock out and shortage of material.

* On time delivery to customer and Increase demand visibility without

worried about inventory.

* Reduce rejection of raw material by 15%.

Holcim Dundee, MI

Jan 2007 - June

2007

http://www.holcim.com/US

Sr.

Analyst

Holcim is the world's second largest cement manufacturing group. Having

plants and offices more then 20 countries. I was involved in SMPPO (Stock

Model Production Planning Operation) model. The model was define in such a

way that it generates Plant wise, Shift wise, day wise, machine wise,

cement type wise production schedule for next 3 months on a given

particular day based on the plant production capacity, plant storage

capacity, plant dispatch capacity and demand forecasting of cement for the

respective plant.

Responsibilities:

* Bifurcating Yearly demand into Quarterly to Monthly to daily (Plant wise,

Cement type wise, Clinker type wise).

* Further segregate daily demand into Plant wise, machine capacity wise and

storage capacity wise.

* Cement production schedule depends on various parameters like (Type of

cement, Type of clinker, machine capacity/OEE(Original Equipment

Efficiency), kiln capacity, machine combination with kiln, storage

capacity of silos, Off peak and On peak hours, electricity cost and labor

availability)

* Along with Cement production schedule we define clinker production

schedule also to maintain stock level of clinker as clinker production is

a continuous process.

* Keeping various constraints into consideration we generate 5 scenarios to

study the impact on cost and production for cement products.

> What if one of the plant shuts down

> What if cement demand increase by 10%

> What if cement demand decrease by 10%

> What if clinker demand increase by 5%

> What if clinker demand decrease by 5%

* Document and diagram the result of all scenarios to better help the

production team.

* Manage customer's Order through EDI and generate Production schedule.

* Daily understand the forecasted/projected production with actual

production and adjust the difference for to rest of the month,

considering required production should not exceed the plant capacity per

day.

* Also define Dispatch/export schedule for cement type via Sea, rail road,

trucks and airways.

Achieved:

* Reduce Production cost by 27% and saves up-to $15M per year by optimizing

off peak hours time

* SMPPO gives exact production schedule for next 3 months at any given day

for any plant or machine

* Simplify daily production and dispatch schedule.

* Reduce overstocked of cement and clinker inventory

* Equally distributed daily production to all machines reduces late

delivery and overtime cost.

Siam City Cement Company. Thailand

Mar 2006 - Nov 2006

http://www.siamcitycement.com/Default.aspx?lang=en

Business Analyst

SCCC is the leading cement manufacturing company in Asian countries. Having

3 plants, SCCC was able to supply different kind of cement across whole

Asian region. AOP (Asian Operation Planning) was developed to prepare

Dispatch schedule for cement from each plant.

Responsibilities:

. Major role involves in Preparing Dispatch schedule of various cement

types from different plant.

. Analyze and prepare report on Plant production capacity, dispatch

capacity, storage capacity.

. Minimize transportation cost by optimizing SCM.

. Define export (Domestic / international) schedule for Cement based on

following parameter

. Total export demand for the day

. Plant production capacity

. Cement and Clinker storage capacity in their respective silos

. Plant dispatch capacity

. Region wise demand and availability of stock in respective warehouse.

. Priority of order

. Also involved in production schedule of various types of cement based on

daily demand.

. Monitoring production & dispatch schedule to avoid any uncertainty.

Achieved:

. Reduce transportation cost by 30% saves $10M per year.

. On time delivery of goods. (export or domestic)

. Equally distributed stock leads to never stock out situation.

Intellicon. Ahmedabad, India

June 2005 - Feb 2006

http://www.intellicon.in/index.html

IT Analyst

In 1992, the formal establishment of Intellicon was effected through a

concerted decision to give a new identity to the flagship company Essen

Tele-communications. After 1996 company involves in Automatic data capture

industry, Industrial Scanner, Bar code solutions, RFID Hand Held Terminals,

Verity of printers.

Responsibilities:

. Did the AS IS systems study and re-engineered with TO BE system study and

documented.

. Plot all the business process activity on the paper in terms of BRD,FRS

and Process flow diagram

. Primary goal is to Implement SAP Business One to integrate various

department, corporate branches and plant.

. Involved in Day to day business process activity and Implementation of

SAP software with the help of HP (Hewlett-Packard implementation team).

. Analyze key Functional area (Financial, Sales & Distribution, Production,

Inventory, Supply chain) and make HP team better understand our business

process to configure software modules to optimize and eliminates paper

work.

Achieved:

. Running optimized smooth operation with SAP B1 and increase productivity.

. Reduce duplication of paper work and save time and cost

. All the departments from various branch office and plant have same

information at same time.

Symphony Comfort Systems Ltd. Ahmedabad, India

May 2004 - June 2005

http://www.symphonycomfort.com/

IT

Analyst

Launched in 1988, Symphony has established as a world leader in evaporative

air coolers, also well-known in air conditioner and water heater with

sensitivity and too good design. Symphony's global popularity is testament

to his sentiment. Its products are already being sold in USA, Europe,

Middle East, Africa, and South Asia.

Responsibilities:

. Implemented VMI system for faster and accurate supply of goods at various

warehouse and dealers.

. Performed system study and collect data for VMI system

. Gathered information about various product and their sizes, also study

geographical location of warehouse and dealers for optimize

transportation cost and truck booking.

. Negotiate with truck dealer to have truck available for on-time shipment.

. Implement auto invoice to customer and

. Integrate all inventory data to the centralize server for faster result

. Engage in truck routing and network design, booking and order priority.

. Preparing Dispatch schedule to minimize Transportation cost, taking

such parameters like (FTL/ HTL., Priority of Order, Area wise

distribution center, Store pick up)

Achieved:

. Improve customer relationships and gain business profit

. Improve on-time delivery and customer satisfaction level by 92%.

. Increase ATP(Available to Promise) ration from 85% to 98%

Mormugao Port Trust, GOA, India

Oct 2001 - May 2004

http://www.mptgoa.com/

Programmer/Business Analyst

Mormugao Port Trust is basically one of the busiest ports in India which

accommodates 100 Ships Daily. To cater the growing business needs, The Port

Operations Management System comes into picture. This Port Operation

Management system comprises of following Modules - Signal Station -Marine

Department, Traffic Department, Planning and Management System, Cargo

Handling labor department, Chief Mechanical Department-Shipping &

Receiving, Central Documentation Centre -Electronic data interchange,

Estate Management System, and Executive Information System.

Responsibilities:

. I was involved in TO BE system study of port business activity, re design

business process and plotted them on paper.

. Prepare FRS, SRS, DFD's, ERD's and activity flow diagram.

. Also involve in Planning and Scheduling of ships for loading and

unloading or iron ore based on (allocation meeting, weather season,

availability of workers, open and close storage area, and domestic export

order for iron ore).

. Study the past Demand of iron ore and prepare demand forecasting chart

for next 3 months.

. Involved in Database design and coding of various modules.

MBA (Marketing/ SCM), B.S. (Production Engineering), Diploma in Advance

Computing (C-DAC)

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