Production management professional with over 9 years experience in large, fast-paced, multi-line facilities. Proven track record of achieving sustained improvements in quality, cost, and delivery functions.
Demonstrated ability to:·
effectively lead, coach, and develop a large work team to accomplish operational objectives.· identify, diagnose and resolve operational, manufacturing, and maintenance problems within deadlines.· plan workflow, manage multiple priorities and meet daily production targets while consistently reducing downtime.· develop new procedures and processes to improve production accuracy.· set up health and safety audit procedures and improve safety efficiencies.· competently utilize Lean Manufacturing, Six Sigma, SPC, and related process improvement techniques to ensure the most cost-effective manufacturing process.· establish and maintain acceptable quality levels for all assigned products.· interpret and develop reports including standard operating procedures.· efficiently set and control operational budgets.
· Provide leadership for the Fabrication and Welding supervisors, leads and associates
· Managed all fabrication operations including personnel and resource optimization
· Prepare daily and weekly work schedules
· Maintaining labor variances and quality standards
· Improved On-time work order percentage from 60% to 82%
· Ensure Superior quality in all Manufacturing processes
· Work with Chinese Technical Assistants in product problem solving.
· Promote harmonious working relationship among all associates including manufacturing associates, Management, Manufacturing, Engineering, and Quality etc
· Check drawings to ensure adherence to design plans without discrepancies
· Assist in development of the weld quality control process
· Planning regular and preventive plant maintenance
· Perform miscellaneous duties as required
· Prepare daily and weekly work schedules
· Ensure availability of all production materials
· Check drawings to ensure adherence to design plans without discrepancies
· Identify and resolve all production problems and issues
· Planning regular and preventive plant maintenance
· Performs process equipment specification development
· Assist in development of the weld quality control process
· Analyze plant production data and in-house test data to make process improvements
· Direct and coordinate technical personnel in performing inspections to ensure compliance with established welding procedures, restrictions, and standards
· Working knowledge of SAW (Submerged Arc Welding), SMAW (Shielded Metal Arc Welding), GMAW (Gas Metal Arc Welding), Gauging process, Cantilever welding machine etc
· Involved in continuous improvement, ongoing quality assurance, ongoing safety improvements, and engineering for conformance
• Managing Analysis, Reporting & Improvement systems of Submarine Construction Division (multi-billion dollar project).• Re-engineer reporting workflows, generate and standardize reporting templates.• Implemented information improvements that significantly improved data quality and stakeholder satisfaction.• Supporting governance for SMC Project-related initiatives based on around 1500 employees.• Support in managing overall project schedule and reporting project status and metrics, including Earned Value Analysis.• Performing schedule variance analysis and cost variance analysis, and implementing corrective action.• Refined PMO process and procedures.• Utilizing organizational and problem-solving skills in supporting Project Director.• Responsible for project reporting and analysis, headcount analysis, and annual resource performance analysis.• Coordinating and administering weekly and monthly Project Reviews - a comprehensive review intended to measure project status and compliance with established project management practices.• Improving and maintaining internal processes in the areas of project management, production & operations management, contract management, facilities management, and communications.• Creating, updating & maintaining all meeting materials, the meeting agenda, presentations, scorecards, and dashboards.• Tracking and updating all decisions, risks, and action items to ensure the project is on track and within the scope as well as following up with team members and management to make sure these issues were resolved.
· Planning material and production activities
· Allocation of resources (Man, Material & Machine)
· Achieve production targets by optimal utilization of all resources.
· Ensure that standardized work has been developed & are followed
· Utilize the DMAIC (Six Sigma) Methodology to minimize process variation.
· Utilize lean manufacturing principles to eliminate wastages from processes and procedures.
· Coordinate with the machine and die maintenance team to eliminate the causes of defects, rework & rejection.
· Prepare & monitor KPIs (OEE, GSPH, Reject Ratio, Down Time, and Rate) to determine trends and areas of improvement.
· Take necessary initiatives to enhance production capacity through Time & Motion study and bottleneck elimination.
· Control and reduce rejections or rework up to the defined limit and maximize throughput yield.
· Lead daily meetings with all team members of departments to discuss and resolve daily issues.
· Responsible for coordinating and planning daily maintenance and repair activities.
· Maintain the stock of necessary spares of critical machines.
· Monitor operational expenses and research ways to reduce costs.
· Maintain and update all documents, systems, and standards/SOPs, interactive process flow charts.
· Maintain safety and regulatory compliance relating to the production facility.
· Achieve production targets by optimal utilization of all resources.
· Take necessary initiatives to enhance production capacity.
· Prepare & closely monitor KPIs (OEE, Reject Ratio, Down Time, and Rate) to determine trends and areas of improvement.
· Control and reduce rejections or rework.
· Take corrective actions emanating from customer complaints and in-house anomaly through the Root Cause Analysis and 5W 1H process to avoid recurrence.
· Responsible for coordinating and planning daily maintenance and repair activities.
· Assist in the preparation of cost-effective OPEX and CAPEX budget proposals and monitor actual expenses incurred.
· Monitor operational expenses and research ways to reduce costs.
· Maintain and update all documents, systems, and standards/SOPs, interactive process flow charts.
· Provide training to team members/operators and develop a few multi-skills workforces.
· Maintain safety and regulatory compliance relating to the production facility.
· Liaison among departments e.g. Inter-department, Support departments (electrical and utilities), PPMC, Store.
· Lead daily quality circle meetings with all team members of departments to discuss and resolve daily issues.
· Verify and update BOM regularly.
· Conducting 5S, ISO & stock audit (Internal & External).
• Planned and coordinated production engineering processes daily to produce high-quality products.
• Provided engineering support for production and maintenance activities to ensure maximum production.
• Assisted in the development of new parts, jigs, and fixtures.
• Performed analysis to reduce downtime and outages.
• Evaluated production activities and make recommendations for improvements.
• Developed operating instructions and equipment specifications.
• Provided training and guidance to team members to accomplish production goals.
• Investigated problems, analyzed root causes and derived solutions.