Manager Engineering

Location:

Nairobi, Nairobi County, Kenya

Posted:

December 05, 2020

Contact this candidate

Resume:

Vishnu K Jayakumar

Tele; +254-*********; +91-807*******

Email: ********@*****.**.**; Skype: roshaero;

LinkedIn: https://in.linkedin.com/in/vishnu-jayakumar-72859417 SUMMARY

• Master’s in Engineering with Specialization in Lean Manufacturing and certified Greenbelt holder Sixsigma.

• Competent and diligent professional with an experience of over 11 years in Operations, Factory Planning, Industrial Engineering, Process Improvement, Quality Control, Cost Management & Manpower Supervision;

• Able to handle challenging Lean six sigma project tasks towards improvement and reduction of cost of poor qualities and reduce Manufacturing Cost in multiple factories.

• Member in American Society of Mechanical Engineers (ASME) member ID 000*********

• Member in Indian Institution of Industrial Engineering (IIIE), Mumbai CORE COMPETENCIES

Operations, Industrial Engineering & Production Planning.

Spearheading continuous improvement (Lean transformation) initiatives in processes.

Create a World Class Shop Floor with "Best in Class" 5S & Visual Factory Standards

Lead a team to achieve the right operational targets (material arrivals to product dispatch) to ensure buyer’s timelines are met.

Participate in Lean initiatives including VSM studies, assess Bottleneck stations and drive improvements towards reducing Cycle times, Set-Up Times.

Drive Capacity improvement Actions and Manpower forecasting including development of new lines in line with Business Needs.

Develop most efficient ways to use people, Machines, Materials, and Information & Energy to make a Product or Service by improving flow and implementing Pull systems.

Creating effective production plan, forecasting, demand plan, execution procedures for the preparation and implementation of programs within the area of industrial safety, health and the environment.

Actively facilitates cross-regional knowledge transferring and establishes assessment process within IE discipline.

Ensure processes are established that ensure first-time quality according to customer requirement and internal guidelines.

CAREER HIGHLIGHTS

1. Atraco Group of Industries (Mombasa Apparel EPZ Limited Unit 3 ) Mombasa, Kenya

As Manager-Industrial Engineering. (April’19- Presently) & (2015- 2016)

• Heading IE/Planning Department for 1300 machine unit with 17 team Members.

• Responsible for cut to pack shipments, quantity & quality control, OCRs, Buyer handling for TCP, JCP, Dickies, Adjmi, VF Asia and Landau Labels.

• Responsible to establish Work Measurement & Improvement Techniques including time studies, ergonomic studies, report Capacity of Machines /Processes & Industrial Efficiency parameters periodically (Weekly & Monthly) and further eliminate waste and implement Standard Work. a

• Responsible to Creating executing production plan for 625K pieces shipments per month with 100% shipments.

• Assist in Financial Planning through Manufacturing Cost Analysis, MMR and factory Budget

• Collaborated with the team members and Top management to maintain a continuous stream of information regarding the complete production details and progress to all related department.

• Weekly production analysis, quarterly planning, demand forecasting for the next 6 months, Implemented PDCA using fish bone, Pareto, why-why analysis to identify root cause for loss of PE/Increase in Cost/min against the set standards.

• Part of core team member which created an ERP of product follow-up from fabric to Container exit stage with size wise tracking which solved most of the problems in the accountability of the Manufacturing process.

• Planned, controlled & monitored all spill over quantities against planned efficiency level and initiate corrective action plan to meet on time delivery.

• Efficiently monitored the Budget Vs. Actual money flow through break even analysis in daily base.

• Calculation OEE and machine breakdown and preventive methods Weekly/Monthly base along with Machine Maintenance team.

2. Shahi Exports Private Limited. 2016 - 2019

Bangalore, India (Knits Division- Unit-20)

As Senior Manager, Operations & Industrial Engineering 1. Cut to Ship responsible of 1000 machines Layout as an Operation manager with Online packing setup with a Shipment of 101%. 2. Responsible for PL of the plant with best Cost per minute results. 3. Compliance requirement adherence for the factory to ensure complete GMP & 5S are sustained. 4. Complete Industrial Engineering responsibility for 1000 machine Layout for Operational Transformation Project at Shahi Exports Pvt. Ltd in consultation with Mckinsey & Co on the below levers:

• Standardization of processes across the unit through module training for supervisors and above.

• Factory level layout optimization. Automation & reduction handling elements.

• Changeover and learning curve loss elimination & reduction.

• Off-standard time reduction with proper Tab implementation, FMEA and IT integration.

• Cutting section fabric feed consistency & tool plan implementation.

• In-process quality improvement for reduction in garment rejections (first time right & defect-based monitoring)

• Line manning architecture (IE prod. system). Skill enhancement of operators, supervisors (training modules on stitching and handling operations)

• Creation of self-governing groups using rewards, recognitions, and group incentives

• Cascaded review architecture and monitoring war-rooms

• Improving on the budgeted vs. actual cost. Improving on the RFT quality.

• Fast Track Line Implementation- 10 days lead time ( Fabric arrival to Loading) Achievements

1. Polo lines reduction of SAM by 3 minutes by best automation in market & detailed Motion and time study using PRO SMV Software.

2. Reduction of helpers in the lines by 35%. Zero Helper Concept Implementation in crewneck and V-necks. 3. Achieved 88% Efficiency on Men’s and Boy’s Polo from the baseline of 70%. 4. Consistent reduction and sustainability of MMR to 1.81 against past data of 2.11 5. Overall cost reduction of $45,776 per month by controlling the Overheads, MMR & OT 6. Centralized Supermarket concept Implementation for Labels, Collars, Peak, Welt-Pocket Operations and Shoulder Attach.

7. Best Performer award for the 5s- Implementation in Knits division-Aug’18. 8. PVH Green rating for the Unit achievement as a team. 3. International British Garments, G4S Group 2013 - 2014 Al Dulayil, Amman, Kingdom of Jordan (Woven)

(Group of companies in India and Jordan)

As Manager, Industrial Engineering and Production Planning.

• Executing Lean Projects in three Units in Jordan.

• Setting up factory plans, production targets and achieve the same within time and cost parameters

• Responsible for overall costing, operational cost, efficiency and productivity of the unit.

• Responsible for generation of production plan, KPI and MIS.

• Value Stream Mapping and process mapping for each Style.

• Time Study, Motion Study, Skill Matrix and OEE Implementation

• Successfully implemented Inline packing System.

• Worked with Modular (Cellular) System, and centralization of cutting.

• Daily manpower, efficiency monitoring line wise in each unit.

• Responsible for generation of Fish Bone, FMEA and Kaizen Activities.

• Quarterly Manpower and Machine planning.

• Weekly/Monthly Shipment planning for better PBITA in Sales.

• Close follow up with Merchandisers, Store and production teams.

• Changing conventional line to Lean Line.

PROJECTS HANDLED

Online Production Changeover for 2 lines with 170 machines.

• Successfully implemented online stitch to packing line.

• Stitch to pack daily closing with less quality issues.

• Factors considered Space, Machine, Manpower, and Ergonomics.

• Highlights are 9% reduction in total manpower, 69% in total Line WIP, 6% in improvement in production, 11% improvement in Efficiency.

Cellular Manufacturing/ Module implementation.

• Successfully implemented modular layout for bottoms Cycle time (SMV) ranges from 6 to 12 minutes, with 4 operators for each cell with 7-8 machines.

• Achieved Highest Efficiency of 92% with inline packing.

• Major benefits, less manpower & WIP, high productivity. 4. CGM Group of Companies 2011 – 2013

Maseru, Kingdom of Lesotho & South Africa (Denim)

(Group of companies in South Africa and Lesotho)

As Manager - Industrial Engineering & Production Planning.

• Time and Motion Study, Line Efficiency generations, 5S and Lean Six Sigma Project Handling.

• Reporting to Factory Manager.

• Handled Denim products. Worked with Levis and Strauss, Edcon, Javelin, Pepe labels

• Assist, lead and perform tasks as required in capital projects that improve productivity, reduce labor cost and improve the quality of the product or process.

• Value Stream Mapping (VSM) and Process Mapping for each product.

• Spend a significant amount of time on plant floor to provide oversight and coaching in the area of LEAN philosophy. Coach employees in the use of LEAN tools (i.e., Six Sigma Analytical Tools and SMED, etc.), LEAN methods and Kaizen events.

• Develop and communicate project plans, schedules, cost, and progress to upper-management.

• Working experience on FMEA, OEE, Layout Designs.

• Develop a continuous improvement culture through an integrated tiered plan-do-check-act (PDCA) management system

• Organize the lean workshop and lean activities to achieve plant lean target.

• Daily Line Balancing, Forecast Report, SMV calculation for each style, and Thread Consumption.

• Making Input plans for the lines in respects of buyers, color, P.O wise and quantity based on the WIP status in lines.

• Making Time & Action Plan (T&A, for cutting only), to have hard look on daily progress report & co- ordinate accordingly.

• Regular meeting with production team for next 3 days inputs availability and smooth flow of inputs to the lines on time.

• Production planning weekly and Monthly, department wise.

• Liaise with Merchandiser for Production folder for new order; Cut projections on date and Short updating

• Working in coordination with Operations team for day to day Plan execution.

• Monitoring the Daily Cutting Reports with updated figure to know the production at a glance.

• Responsible for maintaining Cutting WIP Status and Cutting Efficiency reports for the day. PROJECTS HANDLED

Improving Line Efficiency in Production line in garment Industry. Tools: VSM, Lean Line transformation, Visual Communication, Kanban

Process Improvement in Rivet & Button Section (Packing) section in a garment Industry. Tools: VSM, SMED, OEE

Accessory Storing and retrieving issue solution using Visual Management system. Tools: Visual Controls, 5S, and Kanban

Defect Reduction in hand Sand area in Dry Process Tools: JIDOKA, JIT, TQM

4. Saint Gobain India Pvt Ltd (SEPR) 2008 - 2009

Palakkad, Kerala, India-

As Engineering Trainee – Environmental Health and Safety (Ceramic Industry)

Study Product Requirements & Design Manufacturing & Information Systems including Process Flow Diagrams, Process Control Plans and implement Proactive manufacturing controls including Poke yokes

& Jidokas

Safety Ensure Management and Time and Motion study

Process Optimization and Layout Design and 5S work.

OEE Calculations and TPM Implementing activities.

Improving Yield percentage, reduction of scrap rework and processes.

Lead Time Reduction Methods.

EDUCATIONAL QUALIFICATION

M. Tech - Lean Manufacturing from PSG College of Technology, Anna University in 2009 – 2011

B-Tech – Aeronautical Engineering from JRN Rajasthan Vidyapeeth, Rajasthan, in 2004 –2008

(Approved by AICTE- Delhi as per SC decision dated 03.11.2017 in CA Nos.178**-*****/2017) CERTIFICATION

• Certified Lean Six Sigma Green Belt (CLSSGB) from TUVSUD, South Asia.

• Certified Foundation Course on CATIA from CADD Centre, Palakkad dated 22nd April 2009

• Certified Foundation Course on Mechanical CADD from CADD Centre, Palakkad dated 18th August 2008 SKILLS & EXPERTISE

Lean Manufacturing, Data Analysis, Kaizen, Quality Management, Problem Solving, Value Stream Mapping, Time Study, motion study, Manufacturing, MIS,5S, FMEA, OEE, JIT, Six Sigma, Product Development, Production Planning

IT SKILLS

Operating System: Windows, Mac & Ubuntu

Office Packages: MS office & Open office (Word, PowerPoint, Excel and MS Project)

CAD/CAM/CAE: CATIA V5 and AutoCAD 2010

Simulation Package: Flexsim, Witness 2008, and Rockwell Arena

Lean Package: Igrafx, Leanpilot, Smart draw, Microsoft Visio

SPC Package Minitab v 16

Other ERP-ORGIN PRO, SHIPIT, National Instrument’s Lab View TRAINING

• Participated two day workshop on Lean Manufacturing in PSG College of technology dated 22 &23rd October 2010.

• Participated workshop on Supply chain Management held on 5th August 2010 at PSGIM, Coimbatore.

• Presented a case study in National Case Study competition ‘Benchmark 2011’ held in PSG IM in 25th Feb 2011

LIST OF PUBLICATIONS

Published a Technical paper in National Journal regarding Lean Implementation and Its Benefits, National Journal of Technology; PSG College of Technology (ISSN -0973 -13 34) December - 2012 Volume - 8 Number - 4

Presented a Technical paper in National Conference “Production Optimization and Process Improvement in a Refractory Industry through Lean Implementation”- 11th & 12th March 2011 held in PSG College of Technology.

IN-PLANT TRAININGS

Air India Base, Mumbai, Engine Overhaul Division-15.04.2008 to 14.05.2008

Airport Authority of India, CIA, Coimbatore - October 2007 Languages: Fluent in English, Malayalam & Tamil. Able to manage Kannada & Hindi. India Address: No:3, 4th Street, Udupa Garden, SM Road, Jalhalli Cross, Bangalore, Karnataka Native from Palakkad, Kerala

Date of Birth: 23 February 1987

REFERENCES

Mr. Anil Kumar,

General Manager

Ambattur Clothing Limited

Chennai, India

Mobile: +91-636*******

Email: **********@*****.**.**

Mr. Amar Dave,

Vice president,

Tarasafe International Pvt ltd,

Gujarat, India