PINAKI KAR

PROFILE:

A highly motivated and experienced warehouse & material professional successfully leading and implementing process improvements across all areas of the supply chain / warehousing and teams within global companies.

Demand Planning People Management Warehousing Lean Management ERP Implementation Customer Service

Order Processing Inventory Management 3PL Management

CORE COMPETENCY:

Commercial Operations

Processing of orders, generating Indent, VOR follow up, material allocations, preparing challans, invoicing and accounting of collections.

Managing the store and maintaining reduced inventory levels.

Preparing inbound receipt accounting, and outbound dispatches, reconciliation of stocks, stock report generation and various other reports, ensure GRN are made on time. Tracking Tat Time.

Customer Services

Managing 3PL warehouse (VMI) to ensures on time cyclic deliveries.

Demand management with customer order generation & fulfillment (Customer centric Approach).

Use E-KANBAN for Local suppliers.

Inventory Management

Conducting an inventory analysis to ensure minimal of slow / non-moving components

Planning effective control on inventory, curtail inventory-holding expenses thereby reducing wastage.

Increase inventory turns by optimum inventory & lean management.

Planning

Revenue budget planning & tracking capital expenses.

Monitoring daily issuance to production & ensure replenishment of material through cyclic MILKRUN.

Warehouse Management

Maintaining material stock at optimum defined level. Ensure accuracy @ > 85 % by conducting periodic stock verification and audits.

Implementing processes and SOP’s within the warehouse and training team members for compliance.

Develop & implemented quality packaging solutions (returnable) for internal / external flows.

Ensured on time delivery of material to customers (OEM’s/Distributors) in line with schedule & demands.

Creation of MIS for reviewing holdings and deficiencies of equipment and stock held.

System Operations

Handling SAP – WM module (FF22 Process expert for Plant).

Refining processes, identifying & developing SAP report for End & Key users.

Lean Management/ Projects

Implemented Fixed Bin strategy (Family) for component in stores.

Implemented 3 Bin system (superlative of 2 Bin concept).

5 Day rolling plan for Q parts – Effective visualization & increased inventory turns.

Implemented STL (Ship to Line concept), through KANBAN cards.

Implemented concept of PULL for product families, time window and MILKRUN transportation.

Waste elimination through reverse packaging.

Occupational Contour

S.No

Organization

Designation

Place

Period

1

Escorts-Agri Machinery

Sr Mgr – Stores- FT Division

Faridabad

Feb 2019 ~Aug 2020

2

Tata Motors Limited

Mgr - Head Warehousing (M&HCV)

Sr Mgr – Head – Spare Parts Division

(Reporting to Head – SCM)

Pantnagar

Apr 2014 ~ Sep 2017

Sep 2017 ~ Feb 2019

3

Bosch Limited

(RBIN-Robert Bosch India)

Asst Mgr – Material Mid bound Logistic

In bound Logistic

IPN Planning

(Reporting to Department Head)

Jaipur

Jun 2005 ~ 2009

Jul 2009 ~ 2013

Aug 2013 ~ Mar 2014

4

Ashok Leyland Limited

Sr Exec – Parts

(Reporting to Warehouse Manager)

Delhi

Jaipur

Dec 1994 ~ Jun 2005

5

Carona Cosmetic Pvt Ltd

EDP Assistant

(Reporting to EDP Manager)

Kanpur

Aug 1994 ~ Dec 1994

Responsibilities:

Troubleshoot processes and ensure maintenance of equipment on time by concerned agencies.

Ensured compliance to established standards and achieved production and quality goals.

Accountable for Inbound, mid-bound & outbound, warehouse activities including Processing of Orders, Indent Generation, VOR fulfilment, material allocations, invoicing, accounting of collections (Bill Of Exchange), reconciliation of stocks, Control downtime, line feeding, Dispatches, MIS generation etc.

Budgeting / Capex, Head count to meet production target.

To lead, supervise, motivate Line Leaders and a team of blue collar (On & Off roll both) to meet targets.

Plan strategies to implement revised protocols, standards, procedures, WIS’s as set by Management.

Trouble shoot and possible repairs of on hold materials through Vendor/ Quality Group.

To ensure prompt and accurate recording of material to show correct inventory status of stocks.

Facilitate compliances of TS 16949, ISO 14001(EMS), ISO 18001(OHSAS) through proper documentation.

Conducts perpetual inventory and maintain stock as per stocking / TOC norms.

Ensure & promote safe working culture among team members as per safety standard.

Ensure timely servicing of Vehicle Off Road orders as per set standard.

Plan and coordinate with production to ensure Delivery fulfillment to IPN-CKD customers at right time, right quantity as against order.

Management of 3PL Logistics, having material worth of 400 Mio & 2000 Line components.

To implement SAP Process (WMS) & trouble shooting in Plant.

To ensure improvement of Overall Equipment Effectiveness (OEE) through maintenance.

To facilitate operation management, focus on enhancing (SQCDM) Safety, quality, cost, delivery, & moral.

Development of SQL scripts, slicers, programs for better stock utilization, reports for analysis & reviews.

Monitoring & arranging for disposal of defective stocks

Resolving (Internal & External) customer queries on time.

To drive and ensure deployment of continuous improvement and Kaizen activity.

Impart training to team for material handling and storage.

To ensure part preservation, reduce obsolescence of part through proper packing upkeep of materials.

Identify & support in reduction of cost (in terms of operations, manpower, material, Preservation etc).

Collaborate with team, Part scheduler, other departments, decision makers, Sr management to share information, issues to facilitate strategic calls / decision’s etc.

Manage shelf life parts, ensure FIFO & 5S compliance on shop floor / warehouse.

Achievements:

Started as Green Field Project (M&HCV), achieving 100% CLIP/ CVP through meticulous planning for storage, equipment capability, and timely replenishment of parts.

Achieved Zero Variance in Inventory in first 3 Qtr. and was appreciated by PAN – India SCM Head.

Ensure safe working & accident/ LTI free days in work area through Safety Walks & Capturing Near Miss.

Achieved 100 % process adherence & equipment utilization during material availability at line storage.

Accountable for Inbound & mid-bound logistic, ensure accurate & on time issuance of material at line side.

Optimized Productivity through planning head count, improved processes thereby reduced manpower.

Lead, supervise and motivate Line Leaders and a team of 90 man force to achieve Key Result area.

Attended Daily Morning Production Meeting, Quality meeting, to resolve small issues on timely manner.

Plan strategies for implementation of updated protocols, standards, procedures as set by Management

Optimized storage layout in warehouse to increased productivity, maximize storage space for better traceability, for 3900 unique Part numbers and SKU’s.

Implemented various FIFO procedure, and rolling strategy for bulk items, aggregates.

Optimized stocking of material and increase inventory turn to 48 days through min~max strategy.

Ensure proper documentations of incoming / outgoing stocks and materials to mitigate errors.

Improved process for perpetual Inventory and created Departmental Material health check dashboard.

Implemented visual control in stores through Value Stream Mapping (VSM), was applauded by Plant Mgt.

Reduced Inventory carrying cost & storage space by eliminating obsolete parts, and better parts storage.

Instrument in meeting 24 Kaizen Target by 3PL Operators for the year, highest achievement by any shop.

SPOC for DIFTR “Do It First Time Right” for dept for M&HCV ensure defect free material are line feed.

Coordinator for SLT (Short Lead Time) Project, assessment of core requirement ie Simple Process Flow, Small Lot Packaging, Controlled External transportation, Fixed Ordering system etc.

Implemented Replenishment card process for blue collar and was appreciated by Pan India – Quality Head.

Implemented 3 bin concept in plant for smooth flow of C Class component, reduced -component size from 350 distinct parts to 140 distinct parts. Increased Component foothold.

Played pivotal role in implemented Lean technique using Kanban card, Supermarket concept, visualization and ship to line technique, Just in Time (JIT) resulting in reduction of 12% inventory.

Initiated LOG-PLKZ tool to capture defects and demand corrective actions from suppliers.

Introduced Layered Process Confirmation (LPC) in Inbound, Stores and EHS functions.

Played a pivotal / active role in achieving WCQ Standard Level – I, II & III.

Lead Department coordinator for “PTW” – Permit to work – Du point safety standard.

Increased SPD sales 3 fold by dispatching materials from 30 Cr to 150 Cr to LKO Plant, Central SPD, Northern region Warehouse during Fiscal Year 2017~18 & 2018~19.

95% Vor fulfilment within 48 working hour and 98.5 % monthly SRM fulfillment.

Awarded Best VOR Fulfilment Plant – Pan India.

Reduced Plant Inventory – to the tune of 1.35 Cr through coordinating across Pan India requirement.

Achieved 9.7 service level and customer satisfaction index.

Facilitated control through various internal audit to strengthen processes to eliminate possibilities of error.

Initiated LOG-PLKZ tool to capture defects and demand corrective actions from suppliers.

Introduced Layered Process Confirmation (LPC) in Inbound, Stores and EHS functions.

Appreciated by Plant Mgt for reducing Obsolescence Inventory worth 9 Cr due to BS4 guidelines.

Implemented “Red Tag Campaign” at work area for addressing & resolution of material related grievances.

Dispatched rejected materials within 72 hours.

Played a pivotal role during pandemic Covid by supply of material for export consignment.

Project Handled

Year

Title

Resource

Yield (Benefits)

2019

Pull System – Tyre Feeding

CFT

Reduced tyre inventory at Line side

Optimized Inventory

2018

Central Warehousing

CFT

Inventory Optimization

Lean Process, Increase Productivity

Outsourcing of SPD activity

CFT

Outsourcing of 3PL

2017

Kitting Project

CFT

Lean Inventory

Replenishment Cycle

CFT

Internal Customer satisfaction

2016

Green Packaging Initiative

CFT

Re-cycle packing initiative

2015

Green Field Project

CFT

Capacity Planning, Lean Operation

Outsourcing activity to 3PL

Visual Store

CFT

Lean Standard, Visualization

Dashboard Warehouse

2 Team Player

Transparency, Performance at a glance

2014

Packing Improvement

CFT

Reduced packing cost (3 MINR)

Customer delight

2013

Pull from 3PL Warehouse

CFT

Increase Inventory turns, Reduce Inventory

Consumption based cycle in warding.

2012

Pull from 3PL Warehouse

CFT

JIT Inventory, Increased Inventory turns.

2011

High Rise Storage

2 Team Player

Vertical Space utilization (12 Sq mt)

Advance Shipment Notification

3 Members

Stock Accuracy, improved planning

2010

5 Day Rolling Plan for Q Parts

3 Team Player

Optimum inwarding, Quick Q Clearance

2009

6 day stocking Policy

2 Team Player

Optimized stock (80%) (A Class parts)

Dark Phase Production

2 Team Player

No Production Loss (No SAP System)

2008

One Part One Family

4 Team Player

Quick retrieval of parts, Less errors

Visualisation of Stores

1 Team Player

Planning based on Min~Max level

2007

Optimization of storage space

2 Team Player

Reduction in 4 x 3 Sq Mt space

Inventory Reduction

6 Team Player

Reduced Inventory (400 ~310 Mio)

Awards & Accolades :

Won Best Team Performance award.

Member of CSR Team,

Won award for Quality Problem Solving & Waste Elimination Process.

Editor for Department website.

Won Soccer Trophy, Runners up in Table Tennis, Quarter Finalists in Badminton & Cricket in Plant Sports.

Winner of Poster Competition on Safety, Quality and for ‘Best out of waste’

Won Laurel in Play.

Awarded Silver Medal for TBEM (Tata Business Excellence Model)

Applauded for Consecutive “Zero Variance” in First 3 Quarter inventories.

IT Forte :

Database: Oracle (Sql)

Operating System: UNIX / Dos / Window

SAP (UBK-RM) – R3 - (WM & MM Module)

Trainings:

Effective Front Line Manager. Business

Effective storekeeping & inventory control. Functional

Bosch Production System – Basic. Functional

Process Expert for (WM – FF22) SAP Process Functional

Certified Internal Auditor-TS-16949, ISO 14001, OHSAS 18001 Functional

DBE (Deployment for business excellence) Functional

BGN (Web editor) Coordinator for department. Functional

TBEM (Tata Business Excellence Model) Business

Train the trainer for (Material Handling) Functional

References: https://in.linkedin.com/in/pinakikar

Total Experience:

24 Years

Residential Address:

Flat No-501, Pacific Tower

Omaxe Height

Near Modern DPS School

Sector 86, Faridabad, Harayana

Mobile:

+91 – 982**-*****

+91 – 931**-*****

E-mail Id:

adg6fr@r.postjobfree.com

Skype Id:

adg6fr@r.postjobfree.com

Date of Birth:

21st May 1971

Academic Credential:

Post Graduate Diploma in Management– Supply Chain

Welingkar Institute of Mgt, Mumbai 2018

Post Graduate Diploma in Logistic Management – (Medal Holder)

IIMM, Mumbai, 2009

Diploma in Material Management,

AIMAT, Chennai, 2006

Certificate in Supply Chain (Stood First)

IIT, Delhi & ALVC, 2004

Honours Diploma in System Management,

NIIT, Kanpur, 1994

Bachelor of Commerce – Kanpur University,

Kanpur, 1991

Location Preferences:

Mumbai, Pune, Gujarat, Kolkatta, Bangalore, Chennai, Delhi-NCR, Indore, Abroad.

Domain Preference:

Consumer Electronics / FMCG / Cement / Telecom / Automobile /

Pharmaceutical / IT

Membership:

Member of Indian Institute of Material Management

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