This document provides a summary of G. Sathish Kumar's experience and qualifications. He has over 20 years of experience leading operations and driving efficiency improvements. Some of his achievements include implementing Lean practices that reduced costs by over 90,000 GBP, boosting plant production by 7%, and receiving a 5S Excellence Award. He holds a B.E. in Mechanical Engineering and has led operations and projects in India and international exposure in the US, Germany, France and Italy.

1. G. SATHISH KUMAR
Mobile: +91-7874673174 ~ E-Mail: sathishkrao@yahoo.co.in
Enterprising leader & planner with a strong record of contributions in streamlining operations, enhancing productivity, systems &
procedures, willing to lead Business Operations with an organisation of high repute
SUMMARY
 Dynamic professional with over 20 years of experience in spearheading operations with key
focus on profitability and maximum utilisation of resources through balanced score card
methods
 Skilled in aligning company’s mission & strategic direction to operations and implementing
required objectives to achieve goals
 Facilitated smooth operations of manufacturing units and improved operational efficiency
through Lean implementation
 Expertise in managing green field projects for establishing new industrial units from concept,
layout design to starting / erection and commissioning till stabilizing production
 Gained strong exposure in the implementation of Integrated Management Systems as per ISO
9001, ISO 14001 and OHSAS 18001 standards
 Conceptualized and implemented well-structured 5S program for the entire site which was
adopted by the employees and received 5S Excellence Award from CII Western Region
 Implemented quality control techniques in line with industry / technology trends to achieve product excellence at lowest overall
costs
 Resourceful in representing organization to financial community, major customers, government agencies and shareholders
 Exhibited skills in spearheading the development & implementation of key procurement strategies for plant and machinery from
local as well as overseas suppliers & vendors / contingency plans
Career Growth Path
AREAS OF EXPERTISE
 Developing plans for ensuring smooth plant operations as well as effective
maintenance, manufacturing and customer servicing
 Implementing continuous improvement methods to drive productivity
enhancement and asset utilization
 Curtailing costs by streamlining processes, minimising operational wastage and
executing automation / modernization projects
 Tracking and minimizing the operational expenses & exploring ways to improve
product quality
 Enhancing and implementing critical quality systems in line with the objectives /
milestones
 Guiding the team to develop SWI & JI for all the processes and adhere to laid down
quality and safety aspects
 Coaching the supervisors and monitoring the performance of shop floor people to
ensure efficiency in processes
ORGANIZATIONAL EXPERIENCE
Vesuvius PLC since Sep’10
Vesuvius India Limited, Mehsana, Gujarat as Site Manager since May’14
Foseco India Limited, Pune (Part of Vesuvius PLC) as Plant Manager from Sep’10 - May’14
Role:
 Managing entire operations with balanced score card methodology
 Responsible for planning the CapEx requirements and formulating the annual budgets for delivering the operational results
 Accountable for accomplishing maximum operational efficiencies in terms of inventory days, TMC, equipment efficiency & OTIF
 Ensuring complete compliance to company’s safety standards like ergonomics, work permit systems, LTT, risk assessment,
behavioral based safety and process safety audits
 Maintaining effective utilization of all assets & equipment as well as controlling the capacity – demand management
 Dynamically reviewing the S&OP process as per the customer needs in liaison with the sales force
 Driving continuous employee engagements programs for maintaining a healthy industrial relationship between all levels of
employees

2. Achievements:
 Revamped the costing structure with fewer disturbances to manufacturing process for driving
the manufacturing ERP roll-out
 Exercised control over risk to people and environment through a modernization project
 Curtailed cycle time through 2 operational projects, resulting in 2 manpower reduction
 Eliminated ergonomic issues in one of packaging operations through an automation project
 Sustained consistency and determined the specific process controls which curtailed internal
rejections by 60% within 10 months
 Bagged 5S Excellence Award from CII Western Region for conceptualizing a well-structured 5S
program for entire site
 Contributed net savings of 92K GBP within 14 months through the successful execution of 16
Lean Projects in reliability and industrial efficiency in co-ordination with Solving Efeso (Lean
Manufacturing Consultancy)
 Valued for driving the vertical growth of a supervisory level reportee to line manager position through proper mentoring
 Acknowledged for executing 3 major raw materials import substitutions and presently working on one more substitution, which
delivered recurring savings of 11.4 K GBP annually
 Recognized for increasing in-plant capacity by 4.5% by optimizing the process time with proper evaluation
 Currently leading a corporate level objective “Eliminate Waste” with a target of 150K GBP from all the Indian sites
Saint - Gobain Abrasives, Bangalore from Jan’04 – Aug’10
Joined as a Senior Engineer – Manufacturing Engineering and moved to the position of Manager – Production
As Manager – Production
Role:
 Spearheaded a team of 21 people for leading the entire range of tasks related toplant production, maintenance and critical customer
servicing within 1600 sq. mt. plant
 Responsible for smooth industrial relations with the unionized work force to deliver the required production targets
 Mentored & monitored the contract manufacturing units for their productivity & quality performance to meet the growing demands
 Delivered dual roles as production manager for one SBU and engineering manager for 3 SBUs of the company
 Focused on key factors related to overall performance like target vs. achievement, cost reduction, OTIF, wastage minimization,
capital investments & staffing through monthly reviews with Business Unit Manager & Finance Controller
Achievements:
 Instrumental in boosting the performance of plant to 1.1 million sq. mtrs. shipments consistently every month in 2009; received
recognition for the same
 Effectively minimized the lead time from 12 to 9 days for two high volume products by transitioning work to third party
manufacturer, thereby curtailing the cost by 30%
 Facilitated process re-design and run selected products at higher speed for enhancing plant capacity by 7%
 Imparted shop floor training for all production personnel for implementing 5S concepts throughout the operations
 Accelerated quality consistency of products with lesser investments through a Six-Sigma Project
 Conceptualized and implemented an operator friendly process control troubleshooting check sheet
 Delivered net saving of 28K GPB per annum by developing a low cost product from rejected materials (scraped material)
As Dy. Manager – Manufacturing Engineering
Role:
 Furnishedassistance to 3businessunits regarding their engineering investments witha team of team of Engineers, Supervisorsand
Contract Technicians
 Sanctioned the project plans in coordination with internal customers and ensured timely project completion
 Led the new initiatives related to process automation, capital equipment selection, procurement and tool design &development
Achievements:
 Valued for conceptualizing and spearheading a Greenfield Project for business right from facility design to equipment installation
 Actively involved in market study& cost benefit analysis for investing in an abrasive disc manufacturing line as a Project Champion
 Engaged in studying and manufacturing an equipment in India after customizing design for import substitution through an official
visit to group company in USA
 Instrumental in enhancing process capability and eliminating waste generation by implementing an Online Measurement System
using Nuclear Source (beta ray gauges)
 Initiated 3rdshift activities and seamless operations of equipment by engaging company employees and outsourcing the utilities
function to a specialized facility management agency
 Successfully contributed power savings of 27% by establishing a Compressed Air Networking System across the campus
 Enforced low cost automation in the design of piece processing machine, thereby enhanced the productivity by 30%
 Facilitated the participation of Equipment Operators in maintenance activities by introducing an equipment reliability model

3. PREVIOUS EXPERIENCE
MRF Tyres Limited, Hyderabad/ Pondicherry from Feb’95 – Aug’03
Joined as a Trainee Engineer - Mechanical Maintenance and moved to the position of Senior Engineer - Mechanical
Maintenance
INTERNATIONAL EXPOSURE
 Visit to USA / Germany / France / Italy for manufacturing technology transfers and understanding the designs to build machines
locally for economic reasons
TRAININGS / COURSES ATTENDED
 Lean Six Sigma Practitioner
 Trained 5S Facilitator for Plant
 Self-Practitioner of 7 Habits by Stephen Covey
ACADEMIC DETAIL
 B.E. (Mechanical) from Government College of Engineering, University of Madras in 1993 with First Class
IT Skills:
 ERPs like SAP / JD Edwards and AutoCAD
 MS Office
PERSONAL DETAILS
Date of Birth 3rd July, 1970
Languages Known: English, Tamil, Kannada and Hindi