charles Sahayaraj,C.Eng
Factory Manager
Chennai,TN
Summary
Experienced Engineering Leader with a proven track record of over 25 years in plant maintenance, production, procurement, logistics, and certified Safety officer roles. Specializes in high-speed can end manufacturing and logistics, with expertise in the food & beverage sector as a factory manager. Proficient in SAP (PP, HR), ISO certifications, and Six Sigma methodologies. Strong focus on compliance, crisis response, and cost control strategies to drive continuous improvement processes. Recognized for effective team collaboration and delivering consistent results. Valued for adaptability and reliability in dynamic environments, excelling in operational management and workforce leadership.
Overview
25
25
years of professional experience
1
1
Safety officer from osha
1
1
Internal Auditor from SGS
1
1
HACCP from SGS
1
1
SMART Teacher using AI from Skill net.
1
1
Procurement and Logistic from disaster
1
1
Project Management Essential from Disaster
1
1
Leadership essential from Disaster
1
1
World Class Performance from Crown USA
10
10
years of post-secondary education
Work History
Factory Manager
Refined Food Company
04.2022 - Current
- 29+ years managing production, procurement, and logistics. Reduced breakdowns, optimized spare inventory, and sustained maximum OEE.
- Conducted root cause analyses of production issues to identify areas requiring corrective action or continuous improvement efforts.
- Enhanced factory efficiency by implementing lean manufacturing principles and optimizing production processes.
- Trained and developed staff members, enhancing overall workforce competency and productivity levels.
- Achieved on-time delivery of products by closely monitoring production schedules and coordinating with various departments.
- Developed and maintained a safe working environment by enforcing strict safety policies and procedures.
Production Manager
Refined Food Company
10.1999 - 01.2012
- Raised capacity to 26M can ends/day. Drove process improvements and savings through continuous improvement initiatives.
- Managed multiple projects concurrently, ensuring timely completion and meeting budget constraints.
- Increased overall productivity by identifying bottlenecks in the production process and proposing effective solutions.
- Oversaw quality control efforts, maintaining strict adherence to industry standards and regulatory requirements while achieving high levels of customer satisfaction.
- Fostered a culture of continuous improvement by encouraging open communication between team members and regularly soliciting feedback on operational procedures.
- Managed continuous improvement initiatives to drive gains in quality, flow, and output.
- Collaborated with cross-functional teams to ensure timely delivery of high-quality products according to customer requirements.
- Reviewed work for quality and compliance with company standards and design specifications.
- Resolved issues quickly to maintain productivity goals.
Production Line Engineer
Refined Food Company
10.1988 - 12.1998
- Handled 100-ton presses. Led ISO 9000/14001/22000 certification efforts. Maintained micron-level precision in aluminum can-end production.
- Mentored junior engineers within the team by sharing best practices and knowledge gained from years of experience working at different levels of responsibility.
- Actively participated in safety audits and risk assessments to identify potential hazards and implement corrective actions, ensuring a safe work environment for all team members.
- Coordinated with Quality Assurance teams to address non-conformance issues promptly and prevent reoccurrence in future production runs.
- Developed plans to optimize loop performance, collaborating with manufacturing engineers.
- Provided technical support during equipment installation projects, ensuring timely completion and minimal disruption to production schedules.
- Implemented lean manufacturing techniques, reducing excess inventory and increasing operational efficiency.
- Reduced downtime by implementing preventive maintenance procedures for line machinery.
- Enhanced production efficiency by optimizing assembly line processes and equipment.
- Conducted root cause analysis on production issues, providing actionable insights for continuous improvement initiatives.
- Identified utilization gaps in current work planning, revamping future activities to eliminate waste-producing factors.
- Coordinated selection of manufacturing methods, fabrication, and operation of product designs.
Education
Bachelor of Science - Mechanical Engineering
Insitute of Engineer India AMIE
Kolkatta 06.2009 - 05.2012
MBA - Human Resource
Sikkim Manipal University of Science&Technology
Manipal 06.2008 - 06.2010
Diplomo in Mechanical Engineering 3 Years Course - Mechanical Engineering
Goverment Polytecnic
Trichirappali 01.1980 - 06.1983
Master of Arts - Public Administration
Madurai Kamaraj University
Madurai 06.2005 - 06.2007
Skills
- Maintenance Planning
- Production Scheduling
- Logistics & Procurement
- SAP (PP/HR)
- ISO/HACCP/SQF/OHSAS
- Asset Management
- Risk Management and control
- Project Management
- Professional Certified safety officer by OSHA/USA
- Cost Reduction
- TPM
- Team Development
- Manufacturing technologies
- Machine operation
- Industrial safety
- Waste minimization
- Customer focus
- Manufacturing operations
- Mentoring and training
- Facility management
- ISO standards
- Production planning
- Production reporting
- Cost reduction
- Environmental compliance
- Lean manufacturing
- Six sigma methodologies
- Teamwork
- Teamwork and collaboration
- Problem-solving
- Troubleshooting skills
- Active listening
- Decision-making
- Safety assessment
- Quality control management
- Health and safety compliance
- Forklift operation
Global Exposure
- Attended technical seminars/workshops in Greece, France, and Germany.
- Trained in leadership, SMED, SPC, GMP, fire/rescue drills, and SQF.
- Worked in Jeddah,Industrial city 1 and 2 in different roles and gained plenty of experience in various field
Certification
- Procurement and Logistic Training
- Project Management and its essentials.
- Professional Safety officer by OSHA
- Internal Auditor -SGS Saudiarabia.
- Essential of Budget
- Risk Managements.
Enhance by upgrading my knowledge by updating myself via online platform,self study related to job
Enhancing online skills in chat gpt,AI tools like Gamma,Canva to use in day today life to analyse problems and its application in the work.
Languages
English
Advanced (C1)
Hindi
Intermediate (B1)
Tamil
Advanced (C1)
Arabic
Intermediate (B1)
Malayalam
Upper intermediate (B2)
Accomplishments
- Supervised team of 50 staff members.
- Achieved machine erection by completing and production with accuracy and efficiency.
- Resolved product issue through consumer testing in Can End production
- Collaborated with team of 10 in the development of downgauging the raw material thickness by 0.224 to 0.220mm
- Used Microsoft Excel to develop inventory tracking spreadsheets its a day to day activities
- Achieved excellent result through effectively helping with teams with proper brain storming and root cause analysis
- Documented and resolved issues which led to future team to work on same SOP
Work Availability
monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
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Quote
Every problem is a gift—without problems we would not grow.
Tony Robbins
Software
Micosoft word,ppt,and excel
Using chat gpt,Canva,sora meta AI,adobe express
Able to analyse problems and solution using lot of AI tool
AI application in all the field course-Learning
Completed Smart Teacher course
Interests
Learning new skill in online mode and teaching to high school student when they seek help
Timeline
Factory Manager
Refined Food Company
04.2022 - Current
Bachelor of Science - Mechanical Engineering
Insitute of Engineer India AMIE
06.2009 - 05.2012
MBA - Human Resource
Sikkim Manipal University of Science&Technology
06.2008 - 06.2010
Master of Arts - Public Administration
Madurai Kamaraj University
06.2005 - 06.2007
Production Manager
Refined Food Company
10.1999 - 01.2012
Production Line Engineer
Refined Food Company
10.1988 - 12.1998
Diplomo in Mechanical Engineering 3 Years Course - Mechanical Engineering
Goverment Polytecnic
01.1980 - 06.1983
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