Ashwani Kumar
Assistant Manager –Yarn Manufacturing | Production Operations | New Product Development
Hamirpur
Summary
Textile Engineering professional with 13+ years of experience in yarn manufacturing, spinning operations, production planning, shop floor management, and specialty yarn and new product development. Demonstrated success in driving manufacturing excellence through productivity improvement, process optimization, quality enhancement, cost control, and cross-functional leadership. Experienced in new product commercialization, manpower management, SAP S/4HANA PP implementation, and continuous improvement initiatives within large-scale textile manufacturing operations.
Overview
2
2
Certificates
13
13
years of professional experience
Work History
Assistant Manager
Vardhman Textiles Limited
07.2024 - Current
- Managed end-to-end spinning operations, with responsibility for production, quality, manpower, and delivery targets.
- Led and mentored a workforce of over 85 employees, including shift officers and operators, ensuring production, quality, and delivery targets across 31,680 ring spindles and 720 open-end rotors.
- Optimized 24-hour production schedules to maximize machine utilization and minimize downtime.
- Commissioned two new open-end spinning machines, including installation, product stabilization, and workforce training.
- Served as a Core Team Member for the SAP S/4HANA PP implementation, covering master data, testing, LTMC migration, and user training.
- Improved shop-floor productivity through standardized operating procedures and optimized manpower utilization.
- Ensured compliance with quality, safety, and operational standards.
- Improved manufacturing efficiency through waste reduction and optimized raw material utilization.
- Supported internal and external quality audits by ensuring compliance with standard operating procedures and manufacturing quality requirements.
- Participated in ISO audit preparation, process compliance verification, and implementation of corrective actions.
- Monitored process adherence through SOP implementation and continuous process improvement initiatives.
- Conducted root cause analysis and implemented corrective actions to reduce quality deviations and customer complaints.
New Product Development Engineer, Senior Executive
Vardhman Textiles Limited
03.2020 - 07.2024
- Led the development and commercialization of specialty, mélange, and value-added yarns from concept to bulk production for domestic and export customers.
- Led the Sampling Unit, producing 300 kg per day and 15 customer samples per day, reducing sampling lead time by 25% (from 20 to 15 days) through process optimization and effective resource planning.
- Reduced hard waste by 25%.
- Reduced B-grade generation by 75%.
- Reduced quality complaints by 27%.
- Improved sample OTD from 88% to 90%.
- Implemented BK shade waste utilization.
- Volume 8 launch (1,080 shades).
- First, 100% recycled OE mélange yarn.
- 100% Synthetic Yarn Collection.
- Developed customer-specific, fancy, and mélange yarns based on final knitted fabric appearance, customer specifications, and end-use applications.
- Evaluated newly developed yarns through single jersey, flat knit, and customer-specific knitted fabric trials to validate appearance, performance, and quality before commercialization.
- Developed innovative yarns using natural, synthetic, regenerated, and specialty fibers.
- Optimized fiber blends, dyed fiber percentages, and process parameters to achieve target quality, shade consistency, and production efficiency.
- Collaborated with R&D, PPC, MDC, Quality, Marketing, and Production teams to accelerate new product commercialization, while ensuring on-time customer deliveries.
- Finalized fiber blend compositions, dyed fiber percentages, and shade consistency for mélange and fancy yarns, in coordination with the Melange Development Centre (MDC).
- Ensured end-to-end quality control from fiber selection, through yarn manufacturing, to knitted fabric evaluation, consistently meeting customer specifications.
- Improved manufacturing runnability by resolving process issues during lab dips, sampling, trials, and bulk production through technical analysis and corrective actions.
- Successfully developed and commercialized specialty yarns, including Compact, Siro, Warp, Hosiery, Functional, Jaspe, Spectra Slub, Feather, Snow, Medley, TP-Beauty, Angelina, and Anti-bacterial Yarns.
- Drove continuous improvement initiatives focused on process standardization, fiber mix optimization, waste reduction, and operational efficiency across new product development activities.
- Led cross-functional teams of supervisors and operators during sampling and product development, while ensuring quality, productivity, and timely execution.
Shift Officer, Executive, Senior Executive
Vardhman Textiles Limited
07.2013 - 07.2020
- Managed shift production, manpower allocation, product changeovers, and daily production targets.
- Supervised spinning operations while maintaining quality, productivity, and safety standards.
- Optimized workforce deployment and machine utilization.
- Controlled soft waste and monitored production losses.
- Implemented process improvements to enhance operational efficiency.
- Trained junior officers and operators on production best practices.
Education
B.Tech - Textile Engineering
J.N. Govt. Engineering College
Sundernagar, Mandi06-2013
Skills
SAP S/4HANA PP
Advanced Excel
KPI Monitoring
Team Leadership & motivation
Conflict resolution
Team building
Operations management
Employee performance evaluation
Multitasking and organization
Accomplishments
- Successfully launched Volume-8 Collection comprising approximately 1,080 shades.
- Developed and commercialized the company's first 100% Recycled Mélange Yarn through the Open-End route.
- Successfully launched the 100% Synthetic Yarn Collection across Ring and Vortex spinning technologies.
- Achieved production of 200 MT of Fancy Yarn ("Shahi"), the highest single-shade specialty yarn production.
Certification
2020-03 [PACE Trainer], [Gap Inc.]
Timeline
Assistant Manager
Vardhman Textiles Limited
07.2024 - Current
New Product Development Engineer, Senior Executive
Vardhman Textiles Limited
03.2020 - 07.2024
Shift Officer, Executive, Senior Executive
Vardhman Textiles Limited
07.2013 - 07.2020
B.Tech - Textile Engineering
J.N. Govt. Engineering College
Core Competencies
- Yarn Manufacturing Operations
- Ring & Open-End Spinning
- Innovation
- R&D Collaboration
- Production Planning
- Shop Floor Management
- Specialty Yarn Development
- Product Commercialization
- Customer-Specific Development
- Sampling Unit Management
- Production Optimization
- Lean Manufacturing
- Continuous Process Improvement
- Cost Reduction
- Quality Management
- Manpower Planning
- New Product Development
- Root Cause Analysis & Total productive Maintenance
- Cross-functional Coordination
- Safety Compliance
- SOP Designing and implementation
Technical & Manufacturing Expertise
Yarn & Fiber Expertise
- Mélange Yarn
- Fancy Yarn
- Functional Yarn
- Compact Yarn
- Siro Yarn
- Warp Yarn
- Hosiery Yarn
- Spectra Yarn
- Jaspe yarn
- Flaky & Snow Yarn
- New Product Commercialization
- Specialty Yarn Manufacturing
- Blended yarn
- Fiber Blending & Shade Optimization
- Cotton • Polyester • Viscose • Modal • Bamboo • Linen • Wool • Silk • Nylon • Acrylic
- Specialty Fibers: Sorona®, SeaCell™, EcoVero™, EcoMade™, FeelFresh®, T-Clean®, Silwarm Acrylic, Recrotherm®, Bico Fiber
Quality & Process Knowledge
- Uster 3 & Uster 5 Standards
- Yarn Quality Parameters (RKM, CV%, Imperfections, Hairiness)
- Fiber Quality Evaluation
- Yarn Defect Analysis
- Waste Control & Process Stability