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
Finance Management
Manufacturing Operations
Project Management
People Management
Health & Safety Operations
Supply Chain Management
Quality Management
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
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 in multiple cities
ORGANIZATIONAL EXPERIENCE
Since Mar’07 SAB Miller India Ltd., Sangareddy and Chalakudy
Growth Path:
Mar’07-Oct’08 Junior Executive - Packaging Operations–Sangareddy
Oct’08- Feb’11 Executive- Packaging Operations–Sangareddy
Feb’11-Jul’12 Asst. Manager- Packaging Operations–Sangareddy
Jul’12-Sep’15 Dy. Manager- Packaging Operations–Sangareddy
Sep’ 15-till date Manager-Packaging 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)
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
2. 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 from 37% to 72% over one year after complying the statutary requirement and
spreading the awareness of OCP, resulted “zero” cut injury for the first time in a month
Reduced operating cost by 24 lacs/Annum after modifying the Palletising technology between two production
lines-21000 BPH
Successfully shown 9% improvement in Factory efficiency 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 improving packaging Hygiene 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 21000BPH, highest day production in
36000 BPH and highest month production in the group till the date
TRAININGS ATTENDED
Training on People Management by Nine Dots in 2013
OHSAS Internal Auditor Training by CMSE Mumbai
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
3. 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
PERSONAL DETAILS
Date of Birth:11th April 1981
Permanent Address:Njavarakkattu - House Eruvessi - Post, Kannur, Kerala - 670632
Present Address:H No.-144N, JAAZ Apartments, Parakt Nagar, Near KSRTC, Chalakudy
Languages Known: English, Hindi, Malayalam and Telugu
Passport no: M3295726 issued on 13/11/2014
Skype ID: sunilkumarng