Santhosh Kumar (J)

Production Manager with 14+ years of extensive experience in Manufacturing and Quality management, currently leading operations at Valeo Products in Hyderabad. Proven track record in implementing Lean manufacturing principles, resulting in a 20% increase in Operational efficiency. Expertise in New product development, Process optimisation, and Quality assurance across various industries.

Skilled in Project management methodologies, ERP tools, and Analytical software such as Power BI and Microsoft Excel.

Career goal: to drive Continuous improvement and Operational excellence within dynamic production environments.

PRODUCTION MANAGER - VALEO PRODUCTS - HYDERABAD - Hyderabad

(2024-01)

• Implemented Lean manufacturing principles, resulting in a 20% increase in Overall Equipment Effectiveness (OEE).
• Ensured safe equipment use and scheduled predictive maintenance.
• Operated Niehoff German machines to optimise production efficiency and Ensuring daily usages of materials in ERP.
• Focused on New Product Development (NPD) and researching new applications.
• Produced Solar Panel PV ribbons according to the client's TDS.
• Developed and implemented production strategies closely and monitored results with better efficiency.
• Estimate costs and set the quality standards.
• Implemented and maintained Scrap & Rejection reduction concepts using 3M's.

QUALITY MANAGER - MN AUTO PRODUCTS PVT. LTD. - COIMBATORE - Coimbatore

(2023-01 - 2024-12)

Buzzers, Decorative LED Lamps, Flashers, Melody Makers, Reverse horns, Wiring Harnesses, and much more. Leading manufacturer of auto electrical products for automobiles under the brand name "SUPER".

• Organizing and conducting internal audits (System, Process & Product).
• Coordinating 3rd party & customer audits & implementation of audit findings with addressing Customer Specific Requirements.
• Improvement of process capability for identified quality characteristics with Failure analysis.
• Implemented Quality Functional Deployment (QFD) and Kanban system effectively.
• Using Value Stream Mapping (VSM) tool to destroy non-value activities and concentrate only on valued activities.
• Monitored 7 tools of quality, including CAPA & 8D, to enhance product quality & reduce NC.
• Maintaining the calibration of all equipments and tools in accordance with the methods and procedure established.
• Controlled operational output by implementing quality.
• Reduced workplace incidents by implementing occupational health and safety requirements (OSHAS).
• Submit DPR's, job cards, DWM on performance and progress on daily basis.
• Monitor the production processes and adjust schedules as needed to deliver the goods on time.
• Be responsible for the selection and maintenance of the equipments.
• Set daily, weekly, and monthly objectives, communicating them to all employees by giving adequate trainings.

ASST. PRODUCTION MANAGER - COPTECH WIRE INDUSTRIES - COIMBATORE - Coimbatore

(2017-01 - 2023-12)

Manufacturer of Aqua group (texmo) Flat Cables for submersible motor & pumps.

• Managed manpower allocation across shifts to ensure balanced workload distribution (24 x 7).
• Managed daily operations in production facility, optimising workflow and enhancing efficiency.
• Implemented process optimisation and Lean, Six Sigma concepts to improve productivity.
• Produced PVC wires, cables, winding coils, and profile rods for various applications.
• Coordinated with multiple departments (CFT) to streamline production processes, reduce downtime and costs.
• Stayed up-to-date on industry developments to identify business opportunities to increase production.
• Negotiated and renewed contracts with customers and suppliers.
• Planning job cards according to PO & instructing operators to work according to it.
• Calculating the time taken to complete a job with rated speed for OEE.

PRODUCTION ENGINEER - WIREMANN INDUSTRIES - BENGALURU - Bengaluru

(2016-01 - 2017-12)

Produced Walna, Kopperplant, and Insulon products in a manufacturing facilities to produce Wire, Copper, PVC, XLPE and other cables.

• Expertise in PVC Wires & Cables, Annealed Bare Copper wires.
• Regularly planned and organised maintenance of machinery and equipment.
• Conducted testings as per ISI standards; maintained records and documentation for BIS inspections to support quality assurance.
• Implemented and documented CE, ISI & ISO 9001 standards as Management Representative; conducted monthly MRM meetings to ensure compliance.
• Evaluated strategies to optimise 100% labour utilisation.
• Ensure the safe use of equipment and schedule regular preventive maintenance.
• Identify workers pain area and change that into gain area.
• Evaluate Each Station of the Manufacturing process to ensure maximum efficiency with 100% quality.
• Train New Employees on how to use Machinery safely and follow SOP's.

QUALITY ENGINEER - KAMADHENU WIRES - COIMBATORE - Coimbatore

(2013-01 - 2016-12)

• Implemented and maintained Quality Management System (QMS) to ensure compliance and enhance product quality.
• Addressed customer complaints, warranty issues, and returned products.
• Developed Power-Flex wires and cables to meet industry standards.
• Prepared and submitted reports to managers on product malfunctions with corrective actions.
• Managed documentation for quality assurance activities, ensuring traceability and compliance.
• Checked and recorded incoming raw materials, with quality verification against established specifications and updated it in inventory systems.
• Reviewed customer feedback to identify quality improvement opportunities and enhance customer delight with PDIR.
• Preparing global action plan to improve customer & in-process quality by "Zero Defect Target".
• Preparation of poka yoke concepts and implemented sucessfully.
• Ensuring inspection methods are well documented to ensure compliance within all standards.

MBA - PRODUCTION/HR - KGISL (2017-01 - 2019-12)

B.E - MECHANICAL - Karpagam University (2009-01 - 2013-12)