Manufacturing Plant
Resume:
R E S U M E
VARGHESE PANICKER
Pune
Maharashtra
India.
Mobile: +91-846*******
Email: ********.***@**********.***
CAREER OBJECTIVE:
To be part of a progressive organization where I can utilize my
professional skills and experience under any challenging environment to
achieve the organizational goal.
Professional Experience: Total: 26 years
Company : Mayur Industries Ltd, Sanand, Ahmedabad, Gujarat.
Product : Injection Moulding, Door Trims, Canopies & Tool Room (Auto
Components).
Period : From Oct. 2014 to till date
Designation : Plant Head
Function areas : Production, Stores, Purchasing, Accounts,
Dispatches, Plant Engineering, PQC & Quality
Assurance, Logistics, Accounts, HR/Admin and
Laisoning with Govt. Authorities
Brief Overview:
Profit-driven, results-oriented executive with 26+ years' experience
in the manufacturing of Consumer Electronics white goods, Auto Components
and successful track record of increasing company's net profit. Provide
successful strategic and tactical leadership through a multitude of
business cycles including turnaround, accelerated growth and consolidation.
Drive corporate culture to build powerful operating infrastructures and
high-caliber teams focused on market, customer, and bottom-line
performance. Promote cutting-edge Lean Manufacturing, Six Sigma
Quality, QCD, Line Balancing Efficiency, Supply Chain Management, Kanban,
and Continuous Improvement
initiatives to build high quality, cost-effective operations while
reducing net product costs, inventory level and labor
expenditures. Revamp production and quality processes and construct
solid internal architecture to support and facilitate change-management
initiatives.
Strengths:
Effective and accountable in high-profile role
Overcome Complex business challenges and make high-stakes decisions using
Experience - backed judgment, strong work ethic and irreproachable
Integrity.
Consistent record of delivering extraordinary results in growth, revenue,
operational performance, and profitability.
Consistently deliver mission-critical results
Driven by a visceral "hard-wired" need to strategize, to innovate, and to
disprove the words "It can't be done!" Gifted with the vision,
determination, and skills needed for high-level revenue-building strategies
and tactics.
Strong orientations in operations
Participate in high level operational initiatives, including infrastructure
design, process reengineering, turnaround management, and reorganization.
Respect and leverage human capital
Motivate, mentor and lead talented professionals. Live the culture and lead
by example. Direct cross-functional teams using interactive and
motivational leadership that spurs people to willingly give 100% effort and
loyalty.
EMPLOYMENT HISTORY & FORTES:
. Established Injection Moulding Unit For Ford at Mayur Sanand.
. Established Injection Moulding Unit For Hiaer at Savera Pune.
. Established two new manufacturing plants one at BHARUCH and another at
GANDHIDHAM from scratch during the tenure with VIDEOCON.
. Halted product cost increases through lean manufacturing, supply chain
management, and continuous process improvements.
. Negotiated and obtained major sub contract concessions.
. Eliminated waste and errors through 100% retraining of staff in Lean
Manufacturing techniques and Value Stream Mapping of all departments.
. Achieved mission-critical goals and reinstated pride into workforce.
. Implemented multiyear plan to overhaul and modernize major facilities and
production systems such as Conveyor, HVAC and MRP system.
. Reduced cycle time up to 35% and improved product reliability 50%.
. Recruited staff, created teams, established metrics, and drove
Process improvements.
Key Accomplishments:
. Realized 22% cost savings by introducing outsourcing items for
production of key components.
. Reduced warehouse space 60% and inventory value by 50% through
introduction of Kanban inventory systems.
. Increased productivity 27%, improved on-time delivery 25%, and reduced
downtime failures 75%.
. Eliminated 5% in staffing overhead while improving customer satisfaction.
. Reduced massive scrap and rework expenses 50% and decreased
warranty costs drastically.
. Developed and implemented strategic business plans
. Introduced Lean Manufacturing and Six Sigma activities
. Implemented synergies to utilize commonalities in suppliers, accounting,
and manufacturing best practices.
. Established procedures and processes that addressed safety, quality,
engineering, product reliability, and manufacturing issues at all
manufacturing areas.
. Consolidated product lines and introduced major equipment and plant
upgrades to match the organizational goals.
. Implemented ISO 9001:2000 quality structure at manufacturing
. Cost Innovation through SRT in all areas of operation.
. Implemented JIT & Cash Flow.
. Manufacturing Innovations.
. Sourcing & Research Cost Innovations.
. Process Capability analysis.
. Productivity, Recovery Rate and Line Balancing Efficiency Review.
. Tack Time, Standard Time and Neck Process Review.
. Maintained eco-friendly environment.
1986 to 1989 - JCT Electronics Limited, Chandigarh
1989 to 1992 - Samtel Limited, Ghaziabad.
1992 to 2009 - Videocon Industries, Gandhidham as Plant Head.
2009 to 2012 - Savera Mouldings Pvt. Ltd, Pune as Plant Head.
2012 to 2014 - Vipul S plastocrafts Pvt. Ltd, Pune as Plant Head.
Job Profile:
Plant Head for Injection Mouldings, Assemblies and Tool Room (Auto
Components)
Production Planning and Control:
100% Adherence to the Marketing Requirement.
Quality:
Maintained rejection level of below 100 PPM with 99.9% FTPR quality level
at customer end and more tightened internal PPM Level through increasing
the Eye Level and modern techniques like 6 Tools, 3R, 3W, Cost Innovation,
Manufacturing Innovation and Loss elimination.
Lean Manufacturing:
Developing vendors as the business partners and Marketing as Customers
practiced lean manufacturing system of its class and reduced inventory
levels only for critical items to 1 week and DOL and JIT for the vicinity
vendors.
Pull Card System:
To reduce the inventory level by 50% of Raw Materials and Finished Goods
established Pull Card System. This ensured the timely delivery of FG as per
the marketing requirement as well as the reduction in inventories.
Line Balancing Efficiency:
Increased the Line balancing efficiency in all the assembly lines of CE and
HA with high recovery rate.
Cost Innovation and Manufacturing Innovations:
Initiated and implemented Manufacturing Innovation and Cost Innovation
through Strategic re engineering programs.
Fool Proofing:
Implemented various fool Proofing methods in all the areas of manufacturing
through all employee participation.
TPM:
Involved work man as an integral part of the organization through Cross
Functional / Multi disciplined Teams, implemented the TPM activities and
eliminated the Six Big Losses, thus increased the Efficiency of the Plant.
Man Management:
Rewarded recognized Human Capital on Spot for achievements and implemented
star performer awards on monthly performance basis. Maintained excellent
Harmony, IR through employee involvement and participation in all the areas
of operations. Periodical performance review conducted. Counseled and
handled their grievances professionally.
Problem Solving:
Thorough Statistical process Control systems implemented to avoid the
recurrence of problems.
ACADEMIC CREDENTIALS
MBA Manav Bharati University
B Sc Kerala University,
1984
PDHRD AIMA - CME 1992
Dip. TPM JIM 1994
PROFESSIONAL ENHANCEMENTS
. SAP
. Oracle
. Train the Trainers
. Presentation Skill
. Organizational Behavior
. Performance Appraisal
. Personnel Effectiveness
. JIT, LEAN Manufacturing, KANBAN, etc
Team building.
COMPUTER PROFICIENCY:
My SAP, Oracle, MS Windows, MS Office and Internet Applications
PERSONAL VITAE
Date of Birth : 25-05-1964
Nationality : Indian
Passport No : G5847390
Marital Status : Married with two children (16 and 12 years)
Languages known: English, Hindi, Malayalam (M), Gujarati
Present Salary : 15 lac.+ Perks
Place: Ahmedabad, Gujarat, India.
Date: 12th March, 2015
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