ELAVARASAN MUTHUKUMAR. G
Bangalore
Summary
- Passionate Engineer , 20+ Years of experience in Garment Industry as Industrial Engineer to Operations Head.
- Production Related - Strategic Planning, Quality Control and Trouble Shooting, Setting up the targets and achieve the same by optimizing the MMR.
- Developing the new process / Automation techniques to improve the productivity.
- Spearheaded Continuous improvement and process development initiatives to improve operational performance.
- Implementing the SOP's for the betterment of the working culture.
- formulate long term / short term strategic plans to enhance the operations.
- Focus on Cost Reduction measures , Efficiency Improvement and creating a better working environment.
- Control End to end operations including the Outsourcing.
Overview
25
25
years of professional experience
Work History
DGM - Operations
Shahi Exports Pvt Ltd.
Bangalore
06.2023 - Current
- Production Planning – Factory/ Meet the PCD by following up with Merchandisers and Fabric / Man power Planning / Efficiency / Man Management.
- Responsible for the entire state of the art plant operations of 750 Machines and 1250 Workforces from Cut to Pack.
- Rationalization of Manpower to all departments based on Target Strength Ratio.
- Conduct a daily Production/ Profit & Loss analysis with the respective department heads against the budgeted Cost.
- Coordination with plant for smooth functioning of the production. - Will be responsible for delivering the goods as per the priority.
- Monitoring the Reconciliation of Materials and Garment Closing on a daily / Weekly / Monthly for on time Order Closing.
- Reviewed staff performance regularly using KPIs set out by senior management.
- Researched current technologies available in the market that could benefit the company's operations.
- Established policies related to production processes, quality control measures and safety regulations.
DGM - Operations
Stanfab Apparels
Chennai
04.2017 - 09.2022
- Production Planning / Efficiency / Man Management / Factory Administrations / Responsible for Profit & Loss.
- Responsible for managing entire plant operations from development to production and deliver operational excellence.
- Rationalization of Manpower to all departments based on Target Strength Ratio.
- Analyze cost of all products and assist to reduce negative discrepancy on the same; plan for strategies to reduce wastage and labor cost in all Areas. Conduct a daily Production / Profit & Loss analysis with the respective department heads.
- Coordination with plant for smooth functioning of production. - Will be responsible for delivering the goods as per the priority.
- Responsible for driving various automation projects – that meets companies long term goal and preparing cost benefits analysis and ROI for the same.
- Utilize all the resources to maximize productivity, reduce costs, reduce rejection / rework.
- Provide an effectual interface to all departments; design all strategies and provide assistance to all key staff.
Factory Manager
ColorPlus Fashions Limited
Chennai
11.2007 - 03.2014
- ·Take care of end to end production, quality & maintenance at the company.
- Monthly Production Planning and Ensuring the OTIF.
- Cost control, operational excellence, efficiency, timely delivery and Quality output.
- Monitoring the production status on daily basis and do the successive plans.
- Co-ordinate with Merchandising and Marketing Team.
- Help and motivate all departmental heads towards the company’s goal.
- Man power planning for all the departments
- Cost Reduction in all operational areas.
Manager - Production
Golden Seam Textiles Pvt Ltd.
Bangalore
10.2006 - 11.2007
- Responsible for Entire Production activities of the Plant.
- Monthly Production Plan and follow up.
- Cost control, operational excellence, efficiency, timely delivery and Quality output.
- Monitoring the production status on daily basis.
- Resource Management and Sourcing.
- Training and Development.
- Monitored staff performance and addressed issues.
- Assigned tasks to associates to fit skill levels and maximize team performance.
Executive - Production
MAS - Intimate Clothing Private Limited
Bangalore
04.2005 - 09.2006
- Line Planning and Production Planning according to the delivery dates.
- Responsible for Production & Quality for the Entire shift.
- Prepare Line Manning and allocate the operators accordingly.
- Help the supervisors for balancing the line by simplifying bottleneck operation.
- Organize the Pre-Production Meeting.
- Motivate the Operators to achieve the targets.
- Analyzed production data to identify areas for improvement and cost savings.
Sr. Industrial Engineer
Ambattur Clothing Limited
Chennai
08.2001 - 03.2005
- Production method analysis, Planned Operation Bulletin, Time Study, Line balancing, Operation rate research, Motion economy studies.
- Analyzed process flows to identify areas of inefficiency and recommend solutions for improvement.
- Determined optimal layout designs for manufacturing facilities based on customer requirements.
- Designed automated systems to reduce labor costs while meeting production goals.
- Created process documentation such as standard operating procedures, work instructions and job aids.
- Evaluated existing processes against industry best practices in order to develop continuous improvement initiatives.
- Assisted with the installation of new machinery or equipment according to manufacturer specifications.
- Conducted time studies to analyze current processes and make recommendations for increased efficiency.
Industrial Engineer
Magnum Clothing (P) Limited
Chennai
09.1999 - 07.2001
- Time study, Thread consumption calculation, Operation breakdown, Operator grading, Work method improvements, Production reporting
- Designed efficient layouts of equipment, materials, and workspace to optimize workflow.
- Performed time studies to determine how long certain tasks take so that appropriate staffing levels can be determined.
- Assessed current operational performance metrics and analyzed data trends to identify opportunities for improvement.
- Created detailed reports outlining current operations as well as proposed changes to improve productivity.
Education
Skills
- Industrial Engineering Techniques
- Process Implementation
- Interdepartmental Functions Coordination
- Risk Management
- Teamwork and Collaboration
- Resource Monitoring
- Problem-solving abilities
- Goal attainment
General Achievement
- Improved the Factory's Efficiency and reduced the CPM 30 % by Manpower rationalization and Re-Engg the process.
- Conducted training programs for Managers, Supervisors & Quality People.
- Actively involved in framing the guidelines for 5's and new systems.
- Double the productivity in the sand Blasting Section by applying IE concepts
- Waste Elimination and Cost Control initiatives in all the operational areas.
Consultancy Areas
Industrial Engineering Techniques:
- Study - Method Study /Time Study /Capacity Study /Process Study
- Reduce - Work Content / Cost / Man Power
- Layout - Factory / Line
- Work Place Engineering / Design Work Aids.
- Formats - Operation Bulletin / Data Base for SAM / Method Analysis Report/ Thread Consumption
Production Techniques:
- Line Balancing
- Efficiency / Performance - Factory / Floor / Line / Individual
- Utilization - Man / Machine / Material / Money / Method
- Educate about Target & Quality
Quality:
- Display Mock ups for Every Operator and describe the quality requirements
- Auditing procedures for workmanship, Measurement
- Tolerance Standards for Production.
- Educate the Quality Requirement Standards.
General:
- Factory Set up / SOP / Evaluation / 5S
- Make the Best Working Environment and Culture.
Personal Information
- Father's Name: M.Ganapathi
- Date of Birth: 07/15/77
- Gender: Male
- Nationality: Indian
- Marital Status: Married
References
- Mr. M A Prasad, Ex - COO, Shahi Exports, +91-98453 77111
- Mr. Hitesh Mittal, Product Manager, H&M Group, +91-98108 83758
- Mr. Sreekumar, Ex - Kontoor Quality Head, +91-99712 63899
Affiliations
- Trained by KSA Technopack Team about Work Content Reduction / Waste Elimination / Work Aid Designing / Cost Reduction and Value Engineering Concepts.
Languages
Tamil
First Language
English
Proficient (C2)
C2
Kannada
Upper Intermediate (B2)
B2
Timeline
DGM - Operations
Shahi Exports Pvt Ltd.
06.2023 - Current
DGM - Operations
Stanfab Apparels
04.2017 - 09.2022
Factory Manager
ColorPlus Fashions Limited
11.2007 - 03.2014
Manager - Production
Golden Seam Textiles Pvt Ltd.
10.2006 - 11.2007
Executive - Production
MAS - Intimate Clothing Private Limited
04.2005 - 09.2006
Sr. Industrial Engineer
Ambattur Clothing Limited
08.2001 - 03.2005
Industrial Engineer
Magnum Clothing (P) Limited
09.1999 - 07.2001
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