Production Manager with 11+ years in beverages industry

1. N G Sunil Kumar
Contact: +91-8106822211
E-Mail: sunilkumarng@rediffmail.com
Senior Production/Manufacturing Operations Professional:Enterprising leader &
planner with a strong record of contributions in streamlining operations, invigorating businesses, heightening
productivity and improving systems & procedures
Targeting challenging assignments in: |Production Planning & Control & Manufacturing Operations |
AREAS OF EXPERTISE
Production Planning & Control
Packaging Maintenance
InventoryControl
Health & Safety Practices
Supply Chain Management
Quality Management
Manufacturing Operations
Usage variance control
Project Management
PERSONAL SKILLS
Influencing and leading
Time management
Adaptability
Decision-making
Delegation
Self motivation
PROFILE SUMMARY
 A focused, dynamic Professional with 10 years of experience in Production
Planning & Control, MWay,World Class Manufacturing (WCM) Systems
implementation, Inventory Management and so on
 Proficient in implementing best practices in floor like Team Work, 5S,
Focused Improvement, Visual Performance Management and Safety
 Expertise in working on various WCM aspects from CCI like ITF, DMAIC,
Train the Trainer and monitoring CAPEX system as well
 Expert in quality assurance & control activities involving resource planning,
in-process inspection, team building and coordination with internal/
external departments.
 Manage manufacturing process to ensure product is delivered on time and
under budget while maintaining quality standards.
 Implement and monitor Critical Control Points (CCPs) as an integral part of
a hazard analysis critical control point (HACCP) systemand other elements
of FSSAI certification
 Managing the improvement process by monitoring and revising SOPs.
 Hands-on exposure in Microsoft Office (Word, Excel & PowerPoint) and
Syspro- ERP Package.
 Capable in enhancing the production process operations, optimizing
resource utilization, escalating productivity and operational proficiencies.
 Characterized as a visionary, strategist & team player; consistent record of
delivering results in revenue, performance and profitability by completing
multiple projects.
 Utilize Manufacturing Way strategies to improve manufacturing processes
and reduce costs.
 Ensure safe work environment through implementation of safety
awareness programs and compliance with OHSAS.
 Able to foresee potential problems before they happen.
 Coaching teams and line leaders in best practice methods.
 Working knowledge of all relevant technical and hygiene standards.
ORGANIZATIONAL EXPERIENCE
Since Mar’07 SAB Miller India Ltd., Hyderabad& Cochin.
Growth Path:
Mar’07-Oct’08 Junior Executive - Manufacturing Operations–Sangareddy
Oct’08- Feb’11 Executive- Manufacturing Operations–Sangareddy
Feb’11-Jul’12 Asst. Manager- ManufacturingOperations–Sangareddy
Jul’12-Sep’15 Dy. Manager- ManufacturingOperations–Sangareddy
Sep’ 15-till date Manager-Manufacturing Operations–Chalakudy
Feb’06 - Mar’07 A GI Glaspac-Hindustan Sanitaryware Ltd, Hyderabad as Junior Engineer In-
Plant Engineering Department
Growth Path:
Feb’06 – Feb’06 Diploma Engineer
Feb ‘07 - Mar’07 Junior Engineer - Plant Engineering
Key Result Areas:
 Managing operations, maintenance and planning of RGB-8000 BPH line (Previously 21000BPH and 36000 BPH)

2.  Maintaining day wise tracking of efficiency & consumables usages of the packaging department and week wise
reconciliation of bottles, beer, packaging materials with process and stores departments
 Minimizing the areas of bottlenecks & breakdown; taking steps to achieve zero accident & customer complaints
through continuous monitoring and application of tools like root cause analysis
 Deploying various methodologies for analyzing various processes, recommending modifications to minimize
escalations, reduce rejection, realize operational efficiencies, control variability, costs and reduce cycle-time
 Identifying scope for planning, implementing and monitoring of technological changes for enhancing productivity
 Planning, scheduling & executing preventive & corrective maintenance, troubleshooting of all types of equipment
to increase device up-time, reliability and control quality
 Maintaining a strong communication chain between different divisions in order to receive inquiries about status of
materials, requisition, dispatch information and delivery status
 Monitoring the inventory levels of consumables/ spares/ stocks at warehouses/ stores and ensuring timely
procurement & replenishment of stocks
 Identify good manufacturing practices to control microbiological contamination during food handling and manage
Pest Control and waste materials as part of a Food Safety System
 Developing alternate vendor source for localization, achieving cost effective purchases of raw materials with
reduction in delivery time and improving consistency in quality
 Resolving inventory management related issues which generate during the different kind of Material Movement
activities also wrong inventory valuation, improper master data maintenance
 Functioning on ERP for materials management and production planning Modules
 Timely acting on market complaints and ensuring CAPA in place
 Evaluating the packaging quality scores (PPQA, IQMS, and DPMO)
 Executing plans & schedules for maintenance operations and reducing downtime for enhancing operational
efficiencies with focus on optimum utilization of manpower & materials
Accomplishments:
 Worked as member of a team to gain ISO 18001(OHSAS) Certification and ISO 22000 (FSMS) Certification
 Developed PIMS / POMS table for the Filler Machine as a part of SOP
 Contributed in introducing practices to achieve targets in FFF Packaging Hygiene andTPO %Compliance
 Spearheaded manufacturing way practices- 5S, TW, FI, VPM, and ATM which resulted an improvement of 2.5
GEMS score from 1.2 in WCM practices.
 Improved EHS audit score by 100% over one year after and spreading the awareness of OCP and complying the
requirement.
 Reduced operating cost byINR 24 lacs/Annum after modifying the Palletising technology between two production
lines-21000 BPH.
 Successfully shown 9% improvement in Factoryefficiency through enhancements such as conveyor down time
reduction project and Labeller Vario drive failure reduction in 36000 BPH line
 Achieved a savings of 60 lacs per year after modify the carton errector Mechanism and vendor development in the
material and contracting process in 36000 BPH Line
 Received the best Project award in recognition of Focused Improvement Project on Labelling Glue usage
reduction, which saved INR19Lacs/Year
 Enhanced customer complaint reduction by 70% in a year through implementing the counter measures such as
check weigher monitoring and EBI/FBI maintenance system
 Closed slow feeding issue in the line with in a period of a quarter, which brings up the Efficency improvement by
6% in 21000 BPH line
 Improved training and practice effectiveness resulted in improvingpackagingHygiene score from 70% to 95%
 Carried out manpower reduction in36000BPH line and which gives a straight saving of INR 22 Lacs in pay cost per year
 Reduced Pasturiser breakages from 1% to 0.3% in 21000 BPH, which reflects the savings of INR 30Lacs in terms
of beer, bottle and crown
 Possessed the highest production records like highest day production in 21000 BPH, highest day production in
36000 BPH and highest month production in the group.
TRAININGS ATTENDED
 Leadership fundamentals training by SABMiller Plc in 2016
 IMS Internal auditor training by Bureau Veritas in 2015

3.  Training on People Management by Nine Dots in 2013
 OHSAS Internal Auditor Training by CMSE Mumbai in 2012
 FSMS Internal Auditor Training from Mpath consultants in 2011
 Actively attended the Train the Trainer Programme in CCI, London in 2011
 Advanced Problem Solving Method from CCI, London
EDUCATION
2014 MBA in Operations Management from GITAM University, Vishakapatnam
2012 B.Tech- AMIE in Mechanical Engineering from Institution of Engineers, Kolkata
2005 Diploma in Mechanical Engineering from State Board of Tech Education, Kerala
2002 B.Sc. in Mathematics from Calicut University,Kerala
IT SKILLS
 Proficiency in:
o Microsoft Office (Word, Excel & PowerPoint)
o Syspro- ERP Package
COURSES/ CERTIFICATIONS ATTENDED
 Certificate Course on EHS from IIPH, Gandhinagar in 2015
 General Certificate in Packaging from IBD, UK in 2011
 Advanced Course in CAD-CAM from CITD, Hyderabad in 2005
 Diploma in Computer Application from LBS Center for Science and Technology, Kannur in 2001
PROFESSIONAL AFFILIA TION
 Corporate member in Institution of Engineers (India)
PERSONAL DETAILS
Date of Birth:11th April 1981
Permanent Address:Njavarakkattu - House Eruvessi - Post, Kannur, Kerala - 670632
Present Address:HNo.-144N, JAAZ Apartments, Parakt Nagar, Near KSRTC, Chalakudy,Thrissur,Kerala-680307, IN
Languages Known: English, Hindi, Malayalam and Telugu
Passport no:M3295726 issued on 13/11/2014
Skype ID:sunilkumarng