Operations manager
Blue Steel Factory
Total des années d'expérience :12 years, 1 Mois
• Actively interfaced with vendors and senior management for order expediting, capacity planning, and material forecasts.
• Served on cost savings team, interacting with internal supply groups and business operating teams.
• Introduced manufacturing processes and promoted new technology to minimize customer costs and improved profit margins.
• Established production schedules, defined staffing requirements, and implemented optimized procedures.
• Steered and directed cut and bend manufacturing operations that generate $58M in annual revenue.
• Established operational policies and implemented process improvements to ensure superior quality and outstanding output.
• Directly managed seven departments and overseeing 120+ exempt and non-exempt employees.
• Designed and implemented coaching and training programs to develop staff, facilitate efficiency, and improve performance.
• Managed operational and capital expense budgets exceeding $3M.
• Implemented Just-in-Time (JIT) production methodology to control costs and inventory, resulting in a 40% improvement in efficiency.
• Implemented scrap-reduction measures that minimized waste and maximized production yields to capture recurring annual savings of $1.8M.
• Led Six Sigma and lean manufacturing initiatives that reduced labor costs by 35% while catapulting profitability and productivity by 55% and 35% respectively.
• Preparing cutting list in ARMAOR/ Rebar system and giving to production on daily basis.
• Supervised 350 personnel and 5 foremen facility which produced and delivered $16 million of product annually.
• Increased production levels from 8000 tons to 22000 tons per month (250% increase).
• Moved entire facility to a new location in a period of 15 days with no loss of production.
• Planned daily consumable items used for production.
• Managed the production processes and planned the production schedules needed.
• Optimized the production orders schedule by managing off-cuts and minimizing scrap rate.
• Implemented the assignment of orders on machines and optimization of the production process.
• Prepared and maintained production reports on a daily, weekly, monthly and yearly basis.
• Maximized effectiveness of production team, equipment and materials to produce multi-line products within planned schedules while reducing costs.
• Design training programs for new employees and ongoing projects to improve effectiveness of existing staff.
• Ensured efficient collaboration and co-ordination between relevant departments including procurement, distribution and management
• Assisted with new cost quotes and price quotations for products.
• Developed and implemented production tracking and quality control systems, analyzed production, quality control, maintenance data operational and improved production performance.
• Developed budgets and approved expenditures for supplies and materials, in addition to ensured that materials, labor and equipment are used efficiently to meet production targets and KPIs.
• Reviewed plans and conferred with R&D department to develop new products and processes.
• Maintained current knowledge of the quality control field by statistical analysis and Six sigma studies.
• Reviewed processing schedules and production orders to make decisions concerning inventory requirements, staffing requirements and work procedures considering budgetary limitations and time constraints.
• Providing leadership and coordination of company instrument manufacturing and supply chain functions.
• Developing and implementing manufacturing strategy and aligned supply chain activities to manufacturing strategy.
• Monitoring and analyzing capacity and asset utilization, production schedules, and cost of goods against goals. Focused on continuous improvement and operational efficiency to reduce cost.
• Directing and monitoring department managers to accomplish goals of the manufacturing plans.
• Measuring by quantifiable improvements in supply chain parameters like cost, order fills, order fulfillment cycle times, out of stock ratios, product introduction lead times, manufacturing scrap, warehousing and distribution costs and cycle times.
• Providing manufacturing support for multiple manufacturing plants and operations.
• Responsible for master scheduling of all manufacturing facilities and MRP activities.
• Assisted in the new production system implementation.
• In charge for ISO 9001: 2008 and ISO 18001: 2007 IMS development and implementation.
• Created, Optimized and implemented the internal management workflow to achieve just in time manufacturing.
• Quality and Performance analysis reporting (monthly).
• Proposed and implemented a 5S project in 5 months.
• Detected production line bottlenecks by designing a computer-assisted flow simulation.
• Designed ergonomically efficient workstations for setup time reduction.
• Implemented TQM and TPM Principals inside the factory.
• Reduced scrape rate by 43% (from 4.2% to 1.8%) in 4 months.
• Lowered Setup times by 90% (from 60 minutes to 10 minutes)
• Monitored the development and the production process of the product from the raw material to the final stage.
• Ensured the compliance of the various parameters/points as per customer requirements.
• Coordinated engineering purchases of the Safety and Fire Safety related orders.
• Supervised site activities and ensuring safety and quality measures at site.
• Planned and followed up the production orders and styles.
• Style analysis and conducted research and development of the styles and orders.
• Managed standard time for sewing operations and manual operations.
• Quality check in shearing, Dyeing Various Fastness Tests, Finishing & Packing, Carton Checking and Arranged Final Inspection.
• Negotiating with customers and marketing team pertaining to product rejection/quality issues to understand and solve all customers complaints.
Graduated with a GPA 3.3 with Honor
Completed SAT 1 & SAT 2