SUMMARY:

• 22+ Years of Industry experience in Sales & Operations Planning, Operations Management, Manufacturing & Process Engineering, Master Scheduling and Production Planning, Volume Planning, Product Industrialization, Enterprise Resource Planning, Manufacturing and Customer Order fulfillment, Plant /Facility Management and Maintenance.
• Scientific Approach to Problem Solving, Change Management Process Improvements and product structuring and Family classifications.
• Key user and trainer for ERP - SAP/ M3-Infor and expertise on various ERP systems.
• Annual Savings of $780k leading various cost savings/improvement process line.
• Planned directed and coordinated in creating Master production Schedule from raw material Forecast to final finished goods production by SAP ERP SAP PP/DS,SAP APO AS/400 for Manufacturing Production, flow process lines, assembly lines .
• Formulated managed and supervised Demand Management, Forecasting, Sales Inventory and Operational Planning, supply planning and inventory management, raw material planning, Capacity Planning, Detailed Scheduling and planning .KANBAN for internal and external customers /suppliers, Lean manufacturing and Continuous process improvements.
• Bachelors in Mechanical Engineering
• Facilitate and Lead Work Center Capacity Planning, Finite Capacity Planning.
• Streamline Manufacturing BOM and Product Structure in ERP to support Volume Planning and RCCP.
• Lead Product Family consolidation and change management Process and Manage 15 to 18 months Sales and Operations Planning.
• Drive Inventory Optimization and overall Reduce Inventory carrying cost by 21% in current role.
• Lead supply chain (external and internal) lead time reduction and Increase Customer Service level.
• Facilitate and lead Inventory management, setting up Safety stock, Re-order point.
• Annual Savings of $780k leading various cost savings/improvement process line viz. Schedule optimizations and leveling, Supply process Change, Supply Collaboration, Inventory Management(ERP Order Policy, SS Vs RoP, Vendor Management Inventory/Mini-Market, Process Improvements, Product Family Lead time Optimization ( Labor Hrs Reductions, Kanban / WIP Lot Reductions, Materials Batch Optimizations leveraging Scientific approach to problem solving and process improvements.
• Successful Structuring and industrialization of Engineering BOM to Manufacturing BOM for improved productivity, reduction in cycle time to achieve higher operational effectiveness and excellence.
• A demonstrated 14% reduction in Labor variance Vs standard cost by increased assembly efficiency at reduced cycle time.
• Optimal Material flow Module impacts 23% reduction in Raw material and semi-finished goods Inventory.
• 12% increase of MO Release/ Receipt OTD by integrating adequate planning policies, Detailed Scheduling /Re-Scheduling processes. Improved Productions/assembly procedures and Engineering documentation /instructions.
• Optimal customer demand (Takt and ABC analysis) module to streamline priorities for productions to address capacity constraints and critical customer demands that increased the On Time Delivery by 4 % in addition to increased Customer Satisfaction and Service label.
• Annual savings of $56k by spot kaizen event conducted by self to increase yield, reduced setup time, and reduced scrap production, synchronized material flow.
• Set up KANBAN (raw material->semi-finished->finished->logistics) for optimal material utilization maintaining minimal inventory cost and increased ON TIME DELIVERY for key customers.
• Setting up risk-mitigation plan coupled with Increased Forecast Accuracy for raw material supply to reduce vendor stock outs and increase Supplier OTD.
• Key user and trainer for SAP roll out and training for the floor in each and every work station and work center. Creation and Implementation of Finite capacity Planning for multiple Work Centers/Production Lines.
• Design and in corporate Optimal Demand and Supply model by Product family to support ETO/ATO/ MTS/MTO for increased OTD, Service Levels, Cash Flow.
• Member of BPD for Capex spending, H-K Goals and Strategy deployment .
• Set up and Maintain SLA and SD for intercompany orders.
• Provide on-going training and coaching for the core team leaders and operators in the floor for managing various production metrics,RCA’s,A3’s, VSM’s, APICS CPIM Certification Processes, KPI's, 5S+1, Heijunka(level loading and production smoothening) boards, countermeasure sheets, SPQDC boards.
• Goal-oriented professional with 22+ years of diversified experience in Manufacturing Production Management, Demand Management, Manufacturing Planning and control(MPC), Sales and Operations Planning(S&OP),Enterprise Resource Planning(ERP),Master Production Scheduling(MPS),Rough-Cut Capacity Planning(RCCP),Material Requirement Planning(MRP),Capacity Requirement Planning, Production Planning, Raw Material planning and forecasting, Process Scheduling, Supply chain Management, Inventory Management, Materials Management. Worked as a Processing Production Demand and Supply Planner, Plant Manager, Production Planning Manager, Logistics Sales & Marketing Manager, Manager-Warehousing, Lead Production Planner and Cost analyst, Quality Manager.
• Capabilities to evaluate historical data to identify trends, seasonality and variations to factor in forecasting accuracy .
• Communication and analytical abilities to drive clarity in information flow to ease decision making process among key stakeholders.
• Developed Analyzed and Directed Demand Planning, forecasting, Supply Planning, Inventory Planning and management, Cycle counting, Master Scheduling, Resource Planning, Priority Planning, Capacity Planning, Process Flow charting, Production Planning, Sales and Operations Planning.
• Planned directed and coordinated in creating Master production Schedule from raw material Forecast to final finished goods production by INFOR M3,SAP ERP SAP PP/DS,SAP APO AS/400 for Manufacturing Production, flow process lines, assembly lines .
• Good conceptual engineering aptitude, mechanical aptitude of Plant production/Process line, Plant Operations, maintenance shut-down planning and Statistical data and reports analysis ability to define process problems, identify cause and in corporate solutions.
• Supervised and managed the team to meet Customer demands as well as business requirements, workflow synchronicity, optimal material flow and manpower allocation to sustain productivity demand.
• Supervised execution of Customer orders, delivery orders, inventory management, third-party inspection and Quality Clearance Certificates, creating requirement documents, use cases and test plans.
• Formulated managed and supervised Demand Management, supply planning and inventory management, raw material planning, semi-finished /finished goods planning .KANBAN for internal and external customers /suppliers, Lean manufacturing and Continuous process improvements.
• Coordinate training activities relative to safety management and plant safety.
• Developed prepared and orchestrated Operations management tools for Budget sales, Priority planning, Master scheduling, Capacity Planning, productivity metrics, SPQDC, OEE, Production efficiency, Cycle Time and Labor efficiency.
• Expertise in MINITAB, MS Office, MS Project, SQC, SPC.
• Mentored QA Teams and helped them to formulate test cases from the use cases and supervision to attend quality related customer complaints, CAR’s, RTV’s, MRB’s.
• Direct supervision in New Product Project Planning, Managing and Scheduling resources and process stage activities.
• Planned and executed Performance Management, People management, Project Management, Product Management, DMAIC, VSM, FMEA. QRQC’s, APU’s and APICS CPIM.
• Can work independently to achieve and sustain complex production schedules, Replenishment Schedules, Sales Demand, Inventory Targets and turns.
• Strong leadership, management, planning and organization and people skills.
• Progressive thinker, team player, multitasking, troubleshooting and research skills.
• Ability to work in a self-directed, independent manner.
• Reliable, productive and timely in the performance of duties.
• Team player and self-starter with excellent planning, scheduling, routing, allocation, communication, coordination, documentation, project planning and interpersonal skills.
• Proven ability to work under pressure, prioritize and meet deadlines. Open to dynamic work environment and ability to work collaboratively as and with product planner, product/business analysts, testers, developers and other team members in the overall enhancement of industrial product quality.

EMPLOYMENT HISTORY:

Sales & Operation Planning Manager

Confidential, Aston, PA

Responsibilities:

• Collaborate with the leadership and key leads within human resource, sales, marketing, finance, PLMs, operations and supply chain to establish, lead and drive global S&OP process to meet BU’s Financial goals, Cash flow, Customer Relationships and Market expansion.
• Leads and directs a Team of sales -aftermarket sales, planning Leads, logistics & invoicing specialist ensuring availability of capacity and materials to support worldwide sales plan.
• Facilitate discussions between Finance, Operations, Sales and Marketing to develop mitigation plan.
• Creates and Drives goals for this Team that focuses on maximizing the resource utilization, minimizing the product family Lead time, Increasing and sustaining the service level to customers, Communication level to purchase /supply chain team, well directed execution plan for Operations.
• Review and Integrate demand Planning, Sales forecasting, Distribution center replenishment, Interplant Transfers to Inventory Operation Planning.
• Formulate Independent Demands by Product family and Create Master Schedule 12 to 18 months rolling time line.
• Engage with regional sales, marketing, finance and strategic BU leaders to evaluate forecasts vs actual sales ( volume/trend/mix) .
• Evaluate forecast variations beyond promised levels and plan future forecasts (volume/trend/mix).
• Establish Volume Model of Demand Vs Supply to achieve Business Planning.
• Create Master Production schedule availing Mix Model production/supply Capacity.
• Define planning policies, Purchase policies, Replenishment policies, RoP, Safety stock, Inventory classifications, Logistics policies, Forecast policies, DTF, PTF, Planning Horizon, Lot size, Inspection time lines for each and every dependant and Independent requirements .
• Facilitate Pre-S&OP and S&OP cycles meeting with all stake holders and Executives respectively on sales plans, issues, and mitigating plans and actions .
• Conduct weekly MPS meeting to communicate, report the status of the Production Activity Control and Detailed Scheduling Adherence to cross-functional team inclusive of Project Management, Sales and Marketing, Sustaining Engineering and R&D, Product line management, Industrialization Engineering, Operations, Purchasing, Shipping and Logistics team on meeting promised service levels to Internal/external Customers.
• Lead and Manage daily planning meeting to ensure schedule adherence in each and every Work centers to sustain desired COTD,OTD,MOTD etc.
• Manage demand and supply KPI’s and lead risk mitigation and escalation process to strike balance.
• Review and manage supplier service to sustain supplier lead time, Manage critical communication to Productivity - Operation team to minimize MFG lead time.
• Manage resource planning to maintain service level and Customer demands.

Industrial Engineering Manager

Confidential, Aston, PA

Responsibilities:

• Lead the planning and implementation of flow assembly lines, operations improvements.
• Lead Capture and strategic meeting KPI’s viz.MOTD,COTD,SOTD, Industrial Variances.
• Leading and executing product/process analysis for cost reduction, quality improvement, and OEE improvements.
• Define, Measure, Develop, Implement and Sustain operations management metrics and reports to evaluate and audit progress. Implement techniques to improve productivity, increase efficiencies, cut costs, take advantage of opportunities, and maintain state of the art practices.
• Working with Assembly, Planning and Supply Chain, develop and implement appropriate structure within the ERP system to ensure that the right parts are delivered to the right place at the right time to maximize the utilization of labor hours. Lead the development and implementation of detailed work planning and job sequencing using industrial engineering techniques. Lead the development of product and parts flow structure within ERP system for better utilization of existing Operations and Supply Chain personnel.
• Manage the successful transition of new products and technology into Assembly, establishing goals, training team members and evaluating results.
• Participate in concurrent engineering design reviews and support prototyping activities of new product development.
• Manage cost structure associated with Product Industrialization, Marketability and Product shelf life cycle.

Confidential, NJ

Responsibilities:

• Review and Create Long term and Short term Raw material demand Planning.
• Create Master Production schedule for Processing and Production lines .
• Release Material requirement planning, Resource Planning and Capacity requirement planning for Processing and production lines.
• Release Review and Regulate Production exceptions, daily/weekly Supply Planning of Raw materials from supplier warehouse and outside warehouse.
• Analyze safety stock level, Box Qty, EOQ, MPQ and seasonality index, replenishment lead time to required lead time, monitor demand volatility, PTF (Planning time fence), Planning horizon and Lot size.
• Release contingency plan for expedite/critical/line down customers.
• Create daily, weekly, monthly, quarterly Production metrics viz.Schedule attainment, OEE,OTD,Productivity, Time efficiency, Yield, Material utilization, Labor hours utilization, PPLH, Scrap cost, performance KPIs .
• Review and execute continuous process /production improvement to facilitate reduction in setup time, production time, queue time, waiting time, waste, customer lead time.
• Review and Resolve MRP exceptions, Release schedule agreements/purchase orders for raw materials and components necessary to support production plans, and Drive Daily Inventory Management review process including periodic inventory counts, cycle counts, Reverse logistics.
• Meet and Communicate constraints of schedule attainment to respective customer service group, sales and segment leaders and necessitates planning optimization to satisfy customer demands.
• Review delivery and material problems with vendors and suppliers and monitor the progress and follow up on elimination of corrective action plans.
• Ensure that all materials are available on a timely basis to meet production schedules.
• Ageing analysis of raw material, semi-finished and finished goods material to manage optimal inventory and as necessary E&O analysis and disposition to reduce inventory carrying cost.
• Monitoring process and production schedules, material issuance, and system transactions on daily basis with respect to all work orders.
• Supervising quality inspection of finished goods and WIP, Disposition of MDR'S, DMR’S and consolidation of Master production schedule on the basis of non-conformations.
• Planning and scheduling for third party inspection for finished goods ready for shipping.
• Supervising the quality related problems and customer complaints.
• Total shift scheduling, SSD. Scheduling, maintenance shut down scheduling of both mechanical and electrical team.
• Intercompany orders processing, SLA updating, SD clearance in SAP.
• Planning for clearance of materials, shipping methods, Intercompany orders shipping, Container load for export shipments etc.

Production Supervisor

Confidential, NJ

Responsibilities:

• Supervise and manage SPQCD metrics and measures ( Safety, People, Quality, Cost, Delivery) shift-wise whole plant, near-miss opportunities recording and corrective action plans, recordable/ non-recordable opportunities tracking and follow up.
• Manage people for best quality production, highest productivity, highest OEE, lower production cost, setup time reduction and cost, minimal scrap cost, optimal production yield .
• Manage quality product out of all machines and processes, manage best of quality production per customer desired level to best satisfy customers.
• Address shift/daily non-conforming process and production output and collaborate with QA/QC, production, sales to expedite and escalate Schedule adherence and OTD in production floor.
• Drive adherence to daily /weekly Planning schedules and promised OTD and SLA for customers.
• Supervise to best utilize machine, people and materials to put finished goods in stock on time to satisfy customer demand.
• Drive and Supervise Continuous improvements in all machines, reduce scarp cost, increase OEE to increase on time delivery to the customer and increased customer satisfaction.
• Manage and Supervise machine downtime and escalation process with support group.
• Manage Schedule attainment and operations metrics in adherence to production schedules.
• Supervise work force to achieve shift/day production targets, time efficiency and quality.
• Coach employees on following standard works, SOPs, safety regulations, quality standards, delivery targets.
• Manage cross training, employee development programs, Building own work place, work force accountability and empowerment.
• Train workforce on how to manage conflicts in opinions, internal disagreement and/or any hostile environment etc.
• Manage KANBAN ordering/reordering system, supply request through purchase /supply chain group.
• Manage employee attendance/vacation schedules, training, performance evaluation, new hire.

Quality Manager

Confidential, NJ

Responsibilities:

• Maintain Company Quality Standards.
• Improve reliability of existing and new product development process.
• Review products, processes, standard documents and systems on an ongoing basis to sustain process.
• Manage standards on incoming and outgoing inspection process .
• Overseas over product manufacturing process to ensure Quality .
• Participate in daily production meeting with manufacturing team and report on non-conformations.

Plant Manager

Confidential

Responsibilities:

• Facilitate and Lead overall Sales demand, Operations, Production Planning Manufacturing, Factory Maintenance, Quality Assurance and Quality control.
• Formulate and implement effective operations practices and customer relations policies.
• Lead Daily Plant performance review meeting with stake holders, address gap analysis and develop plans for better Safety, Quality, Productivity, Delivery and Cost flow.
• Lead daily operations opportunities, 5S+1,Continuous improvements of equipment utilization, processes, utilities, product quality, waste elimination, plant performance, On time delivery, Customer order fulfillment and adherence to promised service levels.
• Define and analyze various wastes and Gaps in plant operations, Productions and control appropriate corrective action to sustain overall operational performance and productivity.
• Execute future developments, Business Plan Deployment, capital project initiation, plant expansion, new equipment replacements/installations.
• Direct and Monitor employee evaluations strategies, employee developments protocol, Personnel Training and learning process and new hiring opportunities.
• Direct all actions to achieve and sustain quality assurance for all products and Operations Process.
• Lead strategic processes, standards for Inventory control of Raw Material, Semi finished and Finished goods.
• Support and Supervision to Raw Material supply and handling, housekeeping, safety measures.
• Achievements: Record highest production, 20% Productivity Increase, 33% reduction in Raw material carrying cost. 25% set up cycle time reduction, Record PPLH, Record OTD & SLA.

Planning & Logistic manager

Confidential

Responsibilities:

• Create and lead Master Production Schedule for all production lines.
• Collaborate with sales team and lead Shipping/Logistics planning.
• Analyze, Estimate, Manage and report on material and labor utilization for the facility.
• Lead Demand planning for Volume sales, Raw material and Semi-finished product.
• Raw Material Forecasting and Inventory Management.
• Supply Planning of Raw materials from supplier warehouse and outside warehouse.
• Risk mitigation strategy and plan, new product development planning, PPAP, Processing planning.
• Inventory Control and Management of Floor Rejects, WIP and FG materials, Daily monitor and maintenance of Manufacturing Orders (MO),Work Orders(WO), Distribution Orders ( DO) to achieve and sustain high level of inventory accuracy.
• Monitor periodic cycle counts for optimal inventory level, cost and accuracy.
• Manage and review delivery & Quality metrics with vendors/suppliers and lead CAR’s.
• Ageing analysis of raw material, WIP & FG material and disposition plan.
• Supervising quality inspection FG and WIP, Disposition of MDR'S, DMR’S and consolidation of Master production schedule on the basis of non-conformations.
• Manage and lead quality problems and customer complaints.
• Planning for clearance of materials, shipping methods, Intercompany orders shipping, Container load for export shipments etc.

Planning Engineer

Confidential

Responsibilities:

• Sales and Raw material forecasting, Detailed Scheduling, Shipping and Container Planning /Logistics.
• Analysis of forecast accuracy, Cost analysis on planned versus actual material utilization for facility, Labor variance tracking and resource requirement analysis over 6-9 months.