Karthik Kumar

Experienced manufacturing professional with 18 years of progressive expertise across production management, quality systems, manpower planning, and safety compliance. Demonstrated ability to lead large-scale operations, drive performance through TPM and TQM methodologies, and support continuous improvement with hands-on experience in tyres, battery, and consumer goods manufacturing sectors. Strong grounding in ISO standards, lean systems, and IATF audit readiness.

Adept in floor-level execution and cross-functional coordination.

Associate Manager – Manufacturing - Apollo Tyres Ltd. - Chennai

(2019-05)

Led end-to-end manufacturing operations for a team of 300+, improving productivity through structured TPM implementation and daily management systems.

• Reduced product defects by enhancing quality control protocols and standardizing inprocess checks.
• Optimized material flow and reduced inventory overstock by 60% through periodic audits and improved scheduling with the central planning team.
• Supported a safety-first culture by eliminating high-risk operations and training workforce in BBS practices.
• Delivered consistent KPI achievement by integrating QCC and QC Story methodologies into routine operations.

Industrial Engineering Manager - Rialto Enterprises Pvt. Ltd. - Chennai

(2017-11 - 2019-04)

• Developed site-wide manpower optimization strategy, balancing permanent and contract labor to reduce deployment gaps.
• Collaborated with production teams to raise line efficiency and sustain 95% productivity across shifts.
• Spearheaded lean layout redesigns to improve ergonomics and reduce material handling time.
• Facilitated SMETA and ISO audits by ensuring all production documentation met compliance standards.
• Conducted root cause analyses and implemented corrective actions to reduce quality issues and rework.

Deputy Production Manager - Flamagas India Pvt. Ltd. - Chennai

(2015-12 - 2017-10)

Increased assembly area throughput and reduced scrap rates by optimizing manpower and implementing quality training programs.

• Increased assembly area throughput by 76% in 12 weeks by reassigning manpower and optimizing machine usage.
• Reduced scrap rates by 50% by training operators on quality checkpoints and initiating preventive maintenance routines.
• Introduced department KPIs focused on safety, output, and downtime to monitor real-time performance.
• Conducted OEE analysis to identify equipment bottlenecks and improve scheduling accuracy.
• Delivered 15% productivity improvement through workflow standardization and skill-based operator deployment.

Team Member – Manufacturing - Apollo Tyres Ltd. - Chennai

(2011-02 - 2015-12)

Supervised 100+ shop floor staff in radial tyres production, ensuring adherence to daily output targets and leading quality improvement initiatives.

• Supervised 100+ shop floor staff in radial tyres production, ensuring adherence to daily output targets.
• Monitored production data to identify and correct inefficiencies before they impacted shift performance.
• Implemented safety practices that significantly reduced on-floor incidents and improved audit readiness.
• Led quality improvement projects focused on defect prevention and compliance with internal benchmarks.
• Maintained shift reports and provided actionable insights for continuous improvement.

Production Engineer - MRF Tyres Ltd. - Hyderabad

(2010-04 - 2011-01)

Trained new recruits on machine handling and safety, elevated production line efficiency by resolving equipment coordination delays.

• Trained new recruits on machine handling and safety, improving onboarding efficiency.
• Elevated production line efficiency by 76% by resolving equipment coordination delays.
• Managed work schedules to meet order deadlines without compromising quality or operator safety.
• Responded swiftly to bottlenecks with coordinated support, minimizing downtime impact.

Production Officer - Exide Industries Ltd. - Hosur

(2007-07 - 2010-03)

Rolled out a new operator training program and implemented SOP-driven quality checks to improve employee retention and reduce rework.

• Rolled out a new operator training program that improved employee retention and raised team productivity by over 60%.
• Reduced rework and scrap by implementing SOP-driven quality checks.
• Supported production with hands-on technical supervision and line balancing.
• Maintained timely coordination with supply chain for material availability and dispatch.
• Led workplace safety campaigns and 5S drives to enforce clean, hazard-free operations.

Bachelor of Engineering - Mechanical Engineering - Mahendra College of Engineering and Technology (2003-08 - 2007-05)