NIRAJ KUMAR

***,****** ***.********** ******,chittoor,AP- 517001 C: 981******* adhctn@r.postjobfree.com

Executive Profile

Ambitious and dedicated Plant Head who creates strategic alliances with organization leaders

to effectively align with and support key business initiatives. Assertive and enthusiastic with

extensive knowledge of process optimization and unsurpassed work ethic. Builds and retains

high performance teams by hiring, developing and motivating skilled professionals.

Skill Highlights

strategic planning. System

Implementation. Consensus building

techniques. Cost reduction and

containment. Team and Relationship

Building . Processes improvement

strategies. Lean manufacturing and

design improvement specialist.

Used proven methods and cutting age

technology to successfully cut

costs, streamline operations using IE, Six

Sigma and 5's methods and increase

productivity.

Experienced in commencing factory,

sourcing and training manpower.

Core Accomplishments

1. Increased output by 25% by implementing lean manufacturing at Unity garments.

2. Reduced inventory by 35% and improved on time delivery to 96% by using program

evaluation review techniques.

3. Spearhead an employee engagement program, resulting in a 4% decrease in annual

employee turnover.

4. Boosted customer satisfaction rating by 20% in 4 months' time.

5. Grew revenue by 22% in the first year by spearheading and streamlining all areas of

planning and production.

Professional Experience

Worked for MOZTEX SA, Mozambique as a Plant Head .Responsible fo

operations from manufacturing to compliance, sourcing, training and creating employment

to maximum possible number especially for women. Moztex belongs to Aga Khan Group of

companies. Aga khan group is associated with number of social and cultural projects in

various countries for social and cultural developments, as a part of their corporate social

responsibility. Manufacturing in this plant all kind of Ladies, kids and men's wear for

customers in South Africa. Like Monitor, Kingsgate and Barron.

Working tenure was June 2015 to Jan. 2020.

CURRENT JOB PROFILE

1. Manage overall operations of manufacturing plant in order to meet targets on on-time

delivery, improve efficiency, cost reduction and profitability etc.2. Keep monitoring

production status closely and resolving problems affecting production efficiency.3.Liasining

with internal departments and external parties to ensure smooth operation of the

factory.4.Planning and implementing measures to improve production processes with optimal

use of resources, equipment and manpower etc.5.Ensure factory compliance is verified and

adhered to all resources. 6.Perform any other duties as assigned by the management and/or

their designate from time to time.7. Training & motivating more people and creating team

to achieve optimum targets.8. Ensuring No Batch idle/ Zero Production.9.Ensuring 6 S

sustainability in the factory. Monitoring and Maintaining Lean System.10.Ensuring Lean

activities by working with Kaizen Promotion Team / Continuous Improvement

Group.11.Maintaining Visual, Social and Technical Compliance in factory. Experiences

Experiences

A. Worked as AMSCO MANAGER on UNITED NATION DEVELOPMENT PROJECT, posted

at Unity Garments in Ndola, Zambia, as a Factory Manager. AMSCO is African management

Service Company, who takes up various projects all across African continent under the

development and training program in association with UNDP,IFC etc. Customers catered was

FQML, MSA.

Duration was May 2012 to April 2015.

As a factory Head, on this project,my objectives were to set up the factory,run

training programs,groom the locals in various aspects of production and planning,equip them

with supervisory and managerial skill. Making them learn other technical aspects of

garmenting,fine tune the skill set, setting SOP and other value added stuff like embroidery

and printing etc. also help garment industry grow and become self-reliant in garment

manufacturing .Being a labor intensive industry it has tremendous scope to create

employment and help consumers to use locally made product .In this part of world challenges

are many, and resources are limited, so far trained manpower, material and machines are

concerned. so it becomes more challenging for a project head to realize vision into reality

.And within a year, turnover is almost grown by 25% and employment rate has gone up

significantly.

B. Ankit India, Noida, India-Worked as General Manager. In-house capacity of 600

machines and Outhouse production also. Set up one of the factory from inception, and made

it run in 3 months' time. Did business of worth 8.5 million US dollars.

Duration was June 09 to May, 12.Accounts handled were DP, BHS, and New Look etc.

C. Orient craft ltd, Gurgaon,India, Been Senior Manager operations of 400 machines

integrated unit .Worked here for two years, From June,06 to April,09.Buyer worked with

GAP,BANANA REPUBLIC,MARKS AND SPENCER,NAUTICA etc.

D. BL International, Noida, India, worked here for two and half years as Manager

Operations, I was heading 500 machines unit and outhouse production, producing 1 lacs and

fifty thousand pcs a month.

Duration was Nov,03 to May, 06.Buyer handled –Zara, Veramoda, TR, MIM, Villa etc.

E. Started my career with BIRLA VXL LTD., Faridabad, India as a production executive

and got my firsthand experience in Trouser manufacturing. That unit was state-of-art, having

around 250 machines. Machines I dealt with like welt pocket, feed of arm, tandem needle, blind

hem,surging m/c and in finishing Léger, Toppers etc.,all the latest at that time.

Duration of my working here was 5 years. From July 98 to Oct 03.Buyer worked with

GSA, Lewis, and Hagger.

JOB RESPONSIBILITIES Feb 1753

1. Learned and enriched with the craft of the trade over the years of my working tenure

to benefit the organization with the experience and expertise. Well equipped with production

process, operational procedure, quality norms and technical factory compliance.

2.Do capacity assessment of the unit, material management cost effectively, all the

planning and scheduling regarding styles or operations and maintain the supply chain, ensure

inventory is rightly balanced across all section of production for smooth operation. so the

production streamlining is on track. Having right attitude for accepting and implementing

modern systems for improving production.

3.Keep an eye strictly on cost to stretch the profit margin .Analyze monthly plant

operating costs, inventory position, and financial performances. Monitor cash

expenditures, report performance, variances and other details. Reducing value loss and

controlling costing.

4.Draft and prepare cutting room layout, implementation of cutting table planning,

cutting table utilization chart, marker planning, maximizing utilization of fabric, clubbing

markers to maximize productivity etc. Monitor raw material, WIP, coordinate with suppliers

and vendors and ensure that plant doesn't run out of raw material.

5.Technically sound, well versed with industrial Engg.Systems and folders systems, and

good at trouble shooting. Along with team execute highly productive and efficient sewing

technique,method,specifications,cross training multi skills and man power utilization, reduce

throughput time to maximize productivity. Term as efficient garment manufacturing

concept, just-in-time basis, with superior working systems and more importantly quality

given more prime importance.

6.Do audit and determine root cause of current quality problems with corrective action

plan in conjunction with production staff and implement changes and has to eliminate

customer complaints. To manage daily production and conduct regular operations meetings.

7.Keep on maintaining good relationship within the organization and coordination with

central merchandisers, quality teams, administration and personnel department. Also liaison

with various buying office quality and product integrity teams.

8.Wide range of expertise in both type of fabric woven as well as knits but more

competent in woven Produced all range of product in variety of fabric range. Really believe in

integrating relevant management technique incorporating in production like lean

manufacturing, six sigma, 6s,value engg. And inventory control,product safety and plant HR

compliance.

9. Try to keep Machine/workforce ratio to 1:.7 for regular product and 1:.8 for

hi-fashion, cut to ship ratio to 97/98 percent and also keep a check on SMV cost.

10. To maintain high morale amongst operators through training, recognition and

equitable treatment. To assure enough trained labor is available to deal with production

increases/emergencies with minimal amount of overtime, complete control on production

and unit. Very good at mobilizing the resources and get best of them. Anticipate problems,

Proactive and take steps to avoid crisis situations.

Education

PG Diploma in Apparel production Management from ALT-TC,Bangalore in The year 1998.

Graduation from Osmania University in the year 1996.

Additional Information

Date of Birth - 15th Sept., 1972

Passport No. - L1514904

Validity - March 2023

Marital Status - Married

References

1. Mr. Andrew (Country Manager, AMSCO,Zambia) +260-*********

2. Mr. R K Jha (Vice President,Global, Noida, India) +91-981*******

3. Mr.Sami Akther ( MoztexSA,Mozambique) +258-*********

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