Tushar Dhull

Senior Supply Chain & Logistics professional with 19+ years of experience in the Indian automotive industry at Maruti Suzuki. Demonstrated expertise in outbound logistics operations, multi-modal transport (road and rail), stockyard and inventory management, and digital transformation of logistics control systems. Proven track record of driving cost optimisation, on-time delivery excellence, and process innovation in high-volume manufacturing environments.

Experienced in leading cross-functional teams of 400+ members and managing freight budgets exceeding INR 1,200 million.

Assistant Manager – Sales & Dispatch (Outbound Logistics) - Maruti Suzuki India Pvt. Ltd. - Manesar, Haryana

(2007-01 - 2018-10)

• Managed transport planning and outbound logistics operations for Manesar Plant, dispatching 700+ trucks/day to Pan-India dealers via road and rail.
• Led operations for multi-modal distribution (road & rail), managing transshipment hubs and regional stockyards to serve the entire dealer network.
• Reduced truck turnaround time by 40%, generating annual savings of INR 7.8 lakh through process re-engineering and dock scheduling optimisation.
• Designed vehicle stockyard layouts and standard operating processes, improving driver productivity by 18% and Truck-In Truck-Out efficiency by 7%.
• Deployed ABC-FSN analysis on two years of vehicle movement data across 250+ SKUs (3+ billion INR value), improving space utilisation by 32%.
• Implemented Railway Siding in Gujarat and Manesar plants to shift volumes from road to rail, reducing per-unit freight costs and carbon footprint.
• Developed Transit Vehicle Parks (TVPs) near dealer clusters (latest: Kharkhoda TVP) to enable faster last-mile delivery aligned with market demand.
• Spearheaded SAP S&D implementation for finished vehicle invoicing, and led non-transit document digitisation (Form 21, 22, CNG Certificate) via DMS portal.
• Managed reverse logistics operations and ISO 9001, 45001 & 14001 audits. Led 5S and Kaizen initiatives across all stockyard locations.

Assistant Manager – Spare Parts Logistics - Maruti Suzuki India Pvt. Ltd. - Manesar, Haryana

(2018-10 - 2026-06)

• Designed and implemented a centralised Logistics Control Room (LCR) with an integrated digital dashboard to monitor transporter KPIs and analyse GPS data from 20,000+ trips/month (road & rail), enabling real-time exception management and route optimisation.
• Developed optimised routing algorithms using GPS data from 20,000+ monthly trips, achieving potential freight savings of INR 12 million and maintaining 99% on-time delivery with Journey Risk Management (JRM) integration.
• Performed Root Cause Analysis (RCA) on truck packing, routing, and accident/damage data; implemented curtain-carrier technology and revised vehicle packing combinations — reducing domestic vehicle defects by 41% and vehicle defects by 45%, saving INR 2.61 million in repair costs and INR 4.5 million in dealer claim amounts.
• Managed freight budget of INR 1,200 million, including contract renewals, vendor payments, carrier inspections inside plant, and KPI-based transporter performance reviews.
• Developed auto e-way bill creation portal (with PwC) featuring GPS-triggered auto-extension to prevent expiry and reduce manual re-creation effort.
• Trained a team of 32 direct and 400+ indirect employees across stockyard operations, logistics, accessory kitting, documentation, and vendor management.
• Developed training material for supervisors, drivers, and helpers to standardise operations and improve compliance with SOPs.
• Executed Cycle Time Studies to identify bottleneck activities in inter-plant and intra-plant trips, improving overall throughput across the supply chain.
• Implement Supply Planning and Control Tower Operations to provide real-time visibility on consignments.
• Drive process improvements to achieve 99%+ on-time delivery across all locations.

MBA - 5-Year Integrated Programme (Marketing & Operations) - Institute of Management Studies & Research (IMSAR), Maharshi Dayanand University (MDU) (1999-04 - 2004-05)