Operations Manager Supply Chain

SABARIS CHINNAR SURESH KUMAR

857-***-**** Peoria, IL **********@*****.*** LinkedIn

SUMMARY

Results-driven Technical Operations Manager with 10 years of expertise in product development, program management, operations, and manufacturing scale-up across Medical, Automotive, and Textile industries. Demonstrated success in leading technical teams of 70+, optimizing resource planning, and ensuring on-time product launches. Proficient in hardware asset lifecycle management and deploying robust methodologies, securing ISO 9001 and IATF 16949 certifications. Proven track record in managing Plant P&L accountability, driving cost optimization and profitability while aligning operational strategies with business objectives. Enhanced supply chain efficiency and cost-effectiveness by forging strategic vendor partnerships and balancing onsite and offsite operations, delivering improved operational performance and product integrity. EXPERIENCE

Natural Fiber Welding, Inc., USA

Manager, Manufacturing Engineering June 2022 – Nov 2024

● Oversaw plant operations, including P&L accountability, manufacturing, hardware asset management, maintenance, logistics, and on-site safety, health, and regulatory programs (OSHA) with EH&S leadership.

● Managed technical program that implemented DFM strategies and line design for 3+ product, commissioning of 10+ new equipment within $100K–$25M budgets, transitioning production to continuous flow and increasing throughput to 6M units annually (660%).

● Led a team of 10 engineers to establish KPIs for product performance, manufacturing readiness, and risk evaluation, improving resource planning, product quality, and order cycle time that resulted in a 65% reduction in order backlogs.

● Led leadership development and employee engagement initiatives, mentoring 100+ employees with a 33% promotion rate, improving engagement scores by 28%, and reducing turnover by 15% through targeted coaching and career pathing

● Spearheaded strategic planning initiatives to align hardware asset utilization with business objectives through optimizing CAPEX allocation that enhanced operational efficiency and reduced overhead cost by ~20%.

● Deployed PPAP and APQP methodologies to enhance product quality and compliance, while managing Control Plan (CPs) and SPC frameworks that improved cpk from 0.65 to 1.2, ultimately increasing value stream OEE to 65%.

● Established operational capacity by deploying plant capacity models to assess sales requirements and developing strategic plans to leverage toll manufacturers, boosting annual revenue by ~$350K and improving S&OP accuracy to 83%.

● Implemented Six Sigma principles to drive continuous improvement across cross-functional departments, leveraging process data and Kaizen practices, resulting in an 18% increase in operational efficiency. Senior Process Engineer Feb 2022 – June 2022

● Analyzed key production metrics (OEE, FPY, defect rates) to identify issues and automate inefficient processes, improving product accuracy by 35% and saving $100K in resource usage and material waste.

● Introduced IoT and E2E Traceability technologies to document and monitor every step of the production process, ensuring transparency, compliance, and sustainable practices, which improved Customer Satisfaction Score (CSAT) to 8.

● Reduced ~70% manual dependencies in the production line by introducing automation on 5+ hardware assets, collaborating with SMEs across value streams, resulting in a 400% increase in product quality.

● Led launch of 7+ products and 100+ SKUs, transitioning from prototype to full-scale production by applying PEMB practices, including WBS for structured execution, RACI for clear role definition, milestone tracking, risk mitigation, and optimizing resources and trade-offs between technical and business goals.

● Spearheaded process improvements and quality initiatives, including critical control points monitoring, operator training, and process documentation, resulting in a 25% increase in production efficiency and strengthened client trust and partnerships.

● Established and maintained robust documentation controls, including VSM, SOPs, WIs, FMEA, Control Plans, and Operator Training Matrices, integrating risk management frameworks to ensure ISO 9001:2015 compliance, enhance operational consistency, and effectively mitigate process risks. ConMed Corp, USA

Product Development Engineer Jan 2021 – Aug 2021

● Secured a patent for a medical device (homeostatic clip) design and managed the full product development lifecycle, from prototype to production, reducing time-to-market by 15% and ensuring a successful product launch.

● Partnered with Sales and Marketing teams to develop strategies for product placement using market research data, Voice of Customer (VOC) insights, driving $100M+ in revenue.

● Performed design validation on 8+ endoscopic product lines, ensuring superior performance, compliance with medical device standards ISO 13485:2016, and optimized functionality and user safety, resulting in a 12% increase in product revenue.

● Developed comprehensive testing protocols and conducted statistical analyses (Cpk, Ppk) using Minitab to validate design specifications, ensuring successful regulatory approvals and seamless product launches across global markets.

● Worked with cross-functional teams in the design and development of 6+ advanced endoscopic devices, employing CAD modeling using SOLIDWORKS and Finite Element Analysis (FEA) to optimize performance, resulting in ~20% enhanced device durability and compliance with FDA standards.

● Collaborated with R&D and Quality Assurance teams to execute FMEA and establish robust risk mitigation strategies, resulting in a 35% reduction in product failure rates and improved customer satisfaction scores. Assai Food Products, India

Associate Plant Manager Apr 2018 – Aug 2019

● Optimized plant fulfillment operations for a 450K sq. ft. facility with 300+ employees, driving a 10%+ increase in productivity, 98%+ on-time order fulfillment, and 6M cost reduction through Lean methodologies and process automation.

● Developed and implemented hardware asset management strategies leveraging ServiceNow data from service catalogs, incidents, problems, and change applications, improving asset tracking accuracy by 22% and reducing operational costs by 85K.

● Published 10+ live KPI dashboards using SQL and Tableau, enabling real-time tracking of OTD, Order Accuracy, Cost per Order, Fulfillment Cycle Time, and Inventory via ERP/WMS; thus improving decision-making, accelerating project completion by 15%, ensuring seamless operations and timely product launches.

● Developed and implemented cold chain logistics strategies, ensuring freshness and reducing spoilage rates by 30%, directly enhancing product shelf life and enhanced B2B customer base by 130% in FY 2019.

● Collaborated with the R&D team to scale up production of two new product lines, integrating innovative processes that increased revenue by 20M and expanded market share in the region, while adhering to FSSAI and ISO standards.

● Implemented program management best practices, including risk assessment, resource optimization, and performance tracking, improving on-time delivery rates by 12% and increasing overall operational efficiency across 5+ product lines. VRC Industries, India

Product and Process Development Engineer May 2016 – Mar 2018

● Optimized extrusion and weaving processes for HDPE mosquito nets, improving production efficiency by 25% and reducing material waste by ~10%, resulting in annual cost savings of 10M.

● Designed and executed testing protocols for product validation, leveraging SPC tools and root cause analysis to achieve a 40% reduction in defect rates, ensuring compliance with international quality standards.

● Directed 2+ large-scale programs for installing and commissioning advanced machinery, overseeing SAT, safety audits, and operator training, reducing downtime by 20% and enabling the production of high-performance mosquito nets.

● Facilitated stakeholder communications with Product and Finance Managers, conducting ad hoc pricing analyses for 10+ new product rollouts, optimizing pricing strategies and increased profitability by 5% and achieved 95% stakeholder satisfaction rate. PSG Lathe, Pumps and Motors Manufacture, India

Process Engineer July 2013 - Apr 2016

● Evaluated and optimized the design integrity of 7 major tractor components, implementing modifications that reduced manufacturing complexity and saved $1.1M annually.

● Led cross-functional teams and managed upstream/downstream stakeholders at NELCAST during design validation, establishing strategies that effectively scaled complex product lines and streamlined production.

● Collaborated with TAFE’s senior design team to develop and implement fixtures for newly modified components, increasing operational efficiency by 5% and enhancing product reliability by 27%.

● Supported sales, marketing, and manufacturing teams with technical expertise, driving best-in-class customer satisfaction and fostering stronger client relationships.

● Reduced monthly production costs by $5,000 through process optimization and cost-benefit analysis, delivering sustainable financial improvements.

● Monitored 10+ active projects, ensuring timely milestone completion and redefining backlogs to maintain project alignment with strategic goals.

EDUCATION

Northeastern University, GPA 3.8 Boston, MA

Master of Science in Engineering Management Dec 2021 PSG College of Technology, India

Bachelor of Engineering in Mechanical Engineering May 2018 SKILLS

PM Tools: Atlassian Jira, Confluence, Visio, Smartsheets, MS Project, SharePoint, Asana Asset Management Tool: Asset Panda and ServiceNow

Design Tools: SOLIDWORKS, AUTOCAD

Lean Concepts: PDCA, DMAIC, Poka-yoke, Kanban, Kaizen, 5S, VSM, 5 Why, Fishbone, FMEA and 8D Analytical Tools: Advanced Excel, Tableau, Power BI, Salesforce, SQL, R, MS Office

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