Supply Chain Manufacturing

EXPERIENCE SUMMARY: (https://www.linkedin.com/in/sunanda-mitra-03ba955)

Sunanda is a ‘Value Chain Transformation’ specialist with deep expertise in Manufacturing Execution Systems and in lean-enterprise design using ‘Value- stream mapping’ and ‘Theory of constraints’ methods for industries like utilities, telecom, High-tech, financial solution industry, electrical capital equipment manufacturing, FMCG (fast moving consumer goods), Metals, furniture.

Sunanda is an expert in ‘Business Process Re-Engineering’ using ‘Systematic Redesigning’ methodology and Product Development using ‘Concurrent Engineering’ techniques to drastically reduce ‘Design-to-market’ time

Sunanda is an expert of ‘Shop floor optimization’ techniques and has creatively produced designs for integrating Enterprise Plan at level 4 and process control methods at level 2 with an optimized Manufacturing Execution Systems (MES) at level 3 for maximizing throughput and capturing ‘As-built’ record for regulatory reporting

Sunanda Developed a product that improves productivity of buyers by providing real time analytics of material pool, supplier constraints and value chain complex demands at various nodes in the distribution network. This product was based on the Oracle ASCP engine as was aimed at large distributors of perishable commodities

Sunanda created a ‘Lean-Production-Levelling’ application based on ‘HEIJUNKA’ method for maximizing a line ‘thru-put’ for mix-model value streams. This product balances unpredictability of order and stability requirement of a line by enumerating ‘Buckets’ of work content and detailed schedules of every bucket balanced to the TAKT time. This product is successfully tested for a USA based large furniture manufacturer

Sunanda had been a key contributor to the evolution of Oracle Product Data Hub and Product Life Cycle management

RELEVANT EXPERIENCE:

Music Retailing and distributing:

The client is the larget sheet music Distributor of the world. The client wanted to reduce the Order entry time by eliminating approval stages and human touch points by implementing a rule based price modification solution . The rules would automate application of modifiers based on agreed policies marketing strategies. The pricing thus obtained would be consistent and would allow a achieving budgeted profitability numbers.

The scope included, BOM, Advanced Pricing, ASCP and custom Demand Planning solution

Role: Distribution Profit Architect

Tenure: Aug’ 2016 – Nov’2016

Manufacturing ( High tech, Lean, repetitive, Contract/ Outsourced, Process and Poject Manufacturing):

Complex Engineering – Mobility Products: The client is the world’s leading designer and manufacturer of mobility products for all ages. The client wants to install a lean supply chain with high service level, low inventory carrying and improved operation efficiency. Their goal was to promise a true date to the customer and then work the demand efficiently with zero waste thru the supply chain in order to improve profitability.

The Scope includes Global Order Promising, Oracle ASCP, Oracle Configurator and Oracle CTO

oSunanda’s responsibility is to architect the Order promising capability that is based on logistical and stocking constraints in the value chain and delivers the corporation objectives

oA value chain plan that solves revenue maximizing and inventory reduction

Role: Architect- Order Promising

Tenure: Jun’ 2016 – Till Date

Outsourced Manufacturing (Hi-Tech): The client is the world’s largest data communications and tele-communications equipment manufacturer. The client outsourced majority of their manufacturing to third parties in North, South America and in Asia In order to gain cost advantages, quicker innovation to market, greater responsiveness to fluctuating demand and better efficiency in production process. The scope included: Oracle Outsourced Manufacturing, Oracle ASCP, Oracle Collab Planning, iSupplier, Bills Of Materials, PIM, Oracle Advanced Pricing, Oracle CTO, Oracle Purchasing

oSunanda’s responsibility is to create ‘self-sustainable analytics based’ information hub for the client that gives them an informed and organized view of second tier supply chain (Supplier’s supply chain).

oA constraint based planning solution that predicts shortages, pre-empts bottleneck and manages test equipment usages at the Manufacturing partner’s premises with the goal maintaining 90 % fill rate.

oAn automatic Price calculation tool for purchasing the equipments from the suppliers by factoring in component prices (that they negotiated with their supply base: called MR parts), the disposition of committed offtakes of such parts from different MR-suppliers, the turn key parts that the suppliers procure and the year -on-Year gain that the contract manufacturing partners are committed to provide to the client .

o The solution should optimize inventory being carried at the manufacturing partner site to keep ‘Buy-down’ of aged component stock to the minimum.

oThe solution should create a collaborative platform for the manufacturing partners to see the demands and forecasts and commit capacities

Role: Architect- Outsourced Manufacturing

Tenure: July’ 2015 – June’2016

Furniture Manufacturing: The client is the third-largest office furniture manufacturer by dollarized revenue. Sunanda architected ‘Heijunka’ based ‘Production Levelling’ solution for more than twenty value streams across five plants. These value streams are complex and core revenue earners for the client. The scope included: Oracle ASCP, GOP, Flow Manufacturing, APCC, WIP, Bills Of Materials, PIM, MES

oSunanda’s design builds in balance and stability in value streams which have high level of unpredictability. The new orders are promised not later than the corporate objective while at the same time material stocks are rotated such that inventory is managed optimally.

oA rule based ‘Unit (SKU) scheduling method is established to maximize ‘Operational Throughput’ in a mixed model value stream. A ‘Heijunka’ based system for material delivery and unit build orders are created to reduce operational waste and throughput.

oAnother critical component in the ‘Production Leveling – Heijunka’ solution was optimizing the size of packaging based on order line quantity and then keeping the packs together through production and delivery. This has resulted into lowering of overall logistical cost by packing in more units of furniture into available volume of a container

Role: Short Range Planning’ (SRP) architect

Tenure: July’ 2013 – July’2015

Semiconductor: The client was the Middle East’s only major manufacturer of critical ICs used in Defense communication sector and was part of the Saudi Arabia’s economic Offset Program. Sunanda has redefined their Lean supply chain strategy with a view to improving the operation efficiency. Technology scope included : Oracle ASCP, APCC, Flow Manufacturing, WIP, Global Order Promising, Oracle MES

oSunanda’s design has created a stable chain with very minimum high impact -‘exceptions’. Sunanda’s design has eliminated waste by 30 % the overall average lead time of project delivery by 38% .The design has helped them eliminate safety stocks and thus improved ‘Inventory turns’ manifold.

oSunanda implemented Flow Manufacturing model strategy and help them transition the old Job based ‘Manufacturing Execution System’ into a lean ‘Flow based ‘ mixed model capable system with huge improvements on configurability

Role: Value Stream Architect

Tenure: September’ 2010 – March’2011

Material handling and Capital equipment manufacturing: The client is a fortune 500 company and is a leader in heavy duty industrial cranes and ‘Aerial Works Platforms’. Sunanda has architected a demand management process with the following objective: the technology used were (Demantra, Oracle Demand Planning, ASCP and Flow Manufacturing)

oReducing the overall SPIF forecasting cycle to a week from the current 3 weeks

oImprove forecasting accuracy to reduce waste in client’s KANBAN based execution method with a view to improving the operating bottom line for the business globally.

oA leaner value stream. This values stream was then implemented in their factories in Germany

oCreating a hybrid forecasting model for the client which will blend Industrial indices (UMSCENT, PMI, CASESCHIL etc) into Demantra algorithm

Role: Lean Manufacturing Architect

Tenure: Jan 2010 – August ’2010

High Tech and contract manufacturing: The client is a leading provider of gas detection services and manufacturer of ultra high-tech gas detectors for large mines. Sunanda managed and delivered a very critical initiative for the client. Sunanda created a scalable solution which realized company’s objective of moving to Lean based supply chain in three countries (USA, China and France). (Technologies used were Flow Manufacturing, APCC, ASCP, WIP, MES, CTO, )

oHe helped re-organize the lines and shop floor stock points on flow-based lean model to increase through-put and also to maximize operator productivity.

o He set a demand management process that helped the improvement in MAPE number to 10%. This has eliminated safety stock on most of the items and thus has reduced the supply chain operating cost.

oHe produced an optimizing ‘Shipping’ solution, which produces the desired cost savings at the same, time ensures ‘On-time delivery’ success rate of 90 % globally.

oHe created configurator model structures that ensure maximum revenue realization while reducing the overall production lead time by managing ‘model – to – line ‘loading. This creates balanced loading and thus manages the TAKT time better.

Role: Supply Chain Architect

Tenure: Oct 2008 – August ’2009

Steel Manufacturing: Sunanda was the architect for the most of ambitious project by a global steel giant to improve overall supply chain operational efficiency. his solution delivered the following: The technology scope included OPM, MES (Mainframe-based) CTO, i2, Order Management, Fusion middle wire, workflow and BPEL

oA configurable offering across the product range

oTechnology architecture for handshaking Production Performance results, batch production orders, material consumption and resource usage data, orders and constrained planning and detailed scheduling information

oIncreased reusability of ‘slab’s thus improving the bottom line by a substantial percentage points

oRational loading of plants and thus better optimization of the supply chain

oDesign Product Data Hub to hold majority of the configuration data, which can be shared across multiple solution tracks and custom applications.

oCreate configurable attribute-based pricing mechanism, which can price all product line in any geography for any configuration for any pricing situation.

o Designing an abstract search engine to find matches based on configuration attributes

oPresenting solution to the ‘Metal Solution Board’ in Barcelona

Role: Supply Chain Architect

Tenure: Jul’ 2006 – Sept ’2008

Mixed-Model manufacturing (Lean to project manufacturing) Sunanda was the program manager and Six Sigma ‘Black Belt’ nominee for this project for this fortune 10 client The client was looking to improve the overall efficiency of operation and supply chain productivity for the Control equipment, Fractional Horse Power motors, Industrial switchgears, industrial equipment, and Industrial intelligent process controller businesses. The technologies included were (Discrete Manufacturing, Flow manufacturing, project manufacturing, ASCP, Global Order Promising, Inventory Optimization)

oSunanda’s solution had a complex mapping of Constraint based supply chain planning to a primarily manufacturing supply chain encompassing multiple companies.

o The whole India Implementation was taken up as a Six-Sigma project (with thirty Green Belt projects associated with this.

oThe project has the challenge of a complex heterogeneous products, mixed model method-maps, disparate and diverse supply-chains, supply-chain constraints and different KPIs (Key Performance Indicators) for optimizations

oSunanda was also a key member of the Change Management team and contributed heavily to the management of people side of the change processes.

Role: Black Belt Nominee and Program Architect

Tenure: August 2002 – Jul ’2003

Banking Device Manufacturing: Sunanda was the project manager and the solution evangelist for the for a strategic project for largest ATM manufacturer of the world to reduce the overall manufacturing lead time to 2 days from 10 days. The manufacturing practices for the client are changed to adopt ‘Flow manufacturing’ techniques. The ATMs are heavily configurable products. The critical success factor was to put in place a lean CTO supply-chain sourced by ‘Flow-enabled’ manufacturing plants. The Business processes are unique to the client, which require creativity to map into Oracle. Sunanda‘s solution has improved the fill rate of the orders by 30%. It has also reduced the trapped inventory in the global operation and has improved delivery lead-time by managing constraints in the value chain better. The technology used were Flow manufacturing, ASCP, CTO BOM and WIP

Role: CTO- Solution Specialist

Tenure: Jan’ 2005 – Jul ’2005

Electrical capital equipments: The client is a fortune 200 global enterprise. Sunanda introduced and championed DMAIC (SIX-Sigma) based project quality management methods that have been adopted in the CORP’s program management techniques to manage ERP investment.

oHe introduced ‘KANBAN –based’ execution management methods on their FHP and IHP motors manufacturing plants

oSunanda has established the Demand management process through inter organization collaboration for their heavily configurable. This process has increased the Adjusted R-number to 80%. The MAPE has also improved to 10%. The ware houses could better service factor even with 30% reduction in inventory

oHe helped set-up the Enterprise wide ‘Lean CTO Competency Center’ with the client and contributed heavily towards making process templates and solution templates, which were re-used in CTO on a ‘lean flow’ implementation in all other companies of the Group.

oTechnology used were Flow Manufacturing, ASCP, WIP, CTO, Oracle Demand Planning, Discrete manufacturing, Order Management)

Role: Lean-Competency- Design Architect

Tenure: Jul 2003 – May’2005

Lean Manufacturing – Industrial Drive Systems: The client is a leader of Industrial drive systems in Asia. Sunanda was the Solution architect and also a member of the multi- year Program Management board. The technologies used in this project were Oracle Applications, Configurator, RESONANCE, MAXIMO, Oracle Demand Planning, Oracle Field Sales, Field Service, Installed Base). Sunanda designed a C-T-O based business process that:

oReduced the overall engineering engagement volume on the orders and thus improved the turnaround time

oImplemented flow based lines and TAKT time gains in four factories Provided automatic connectivity with PDM capabilities to easily search and retrieve designs from design vault

oAllowed manufacturing in a constraint based planning model and reduced yield

oOptimized the overall product offering mix to reduce waste in the supply chain.

Role: Lean-Program Director / Manufacturing Practice director

Tenure: Feb’1998 – Feb’ 2002

Life Science

Drug Manufacturer: Sunanda architected the demand management process for a new acquisition by a drug major. The forecasting accuracies over a period of 7 months (seven cycles) had improved to below 15 %.( Technologies used were Demantra Demand Management and S&OP)

oSunanda also assessed the impact of Demantra S&OP process deployment over their operations in Israel and Canada

Role: Demand Shaping – Lead Architect

Tenure: Jul 2009 – Dec’2009

Intellectual Properties, Media and Studio

Comic Book and related media and studio: Sunanda designed and led the project for ‘IT-enabling’ their Intellectual property rights contracting business in such a way that it offers a faster turn-around time for the ‘Deal memo – to – Contract’ process, while at the same time improves 360 degree financial management of contracts and offers all relevant pieces of information about rights to do multi-dimensional analysis to sales and executives.

Sunanda’s solution helped the client configure a ‘Right’, ‘Minimum guarantee commitment’ (A character rendition on an article for a territory in a specific language and channel) and manage the ‘Right’ through its lifecycle in the Right’s installed base.

Role: Intellectual Right – Lead Architect

Tenure: March’2005 – Jul’2005

Large scale Distribution

A leading distributor of high assortment of imported Gourmet foods : Sunanda led a four member project team to design and implement Demantra, ASCP and Capgemini’s Buyers Workbench Solution for a Food Distribution company.

oSunanda architected new transportation load building logic to minimize transportation costs and control and limit inventory cost and obsolescence exposure.

Sunanda piloted a spend analysis solution based on Oracle Fusion Procurement with a view to obtaining a saving on the bottom line. The component used in that pilot was Oracle Fusion Procurement

Role: Program Director

Tenure: March’2011 – Feb’2012

Telco:

Largest Pre-paid telecom service provider of USA: Sunanda led the design and implementation of a Product Data Hub using Oracle’s PIM ( 12.1.3) and automatic synchronization choreography to a GDSN data pool The ‘Product Data Hub’ as the single source of truth eliminated 45 complex interfaces in clients overall application landscape and improved the response time to a retailer information request through GDSN by 60 percent The project has provided the client substantial savings in maintenance cost of their applications. Sunanda helped the client build a catalog that enabled easy guided searching for both the customers (on the web store) as well as attribute based searching for client’s engineers for finding parts.

The technologies used are Oracle PIM, Clarify and Clarity.

Role: Program Director

Tenure: May’ 2012 – Jun’2013

TRAINING:

o6 Sigma DMAIC Project Quality Audit

oBPR by ‘Systematic Redesigning’

oProject Life Cycle Management

oManagement of Technology

oISO 9000 and CMM and EVA

oJQI & TQM concepts

HIGHER EDUCATION:

B.E.-Electrical Engineering

-Jadavpur University, India

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