Iyyappan S

Leadership and Team Management:

• Orchestrated all facets of warehouse operations, inventory control, and strategic implementation for a high-volume distribution center.
• Mobilized a large team of 595 indirect reports and 41 direct reports (led by 6 Deputy Managers), fostering a culture of accountability and continuous improvement.
• Mentored and developed team members through performance reviews, identifying growth areas, and aligning KRA goals with collaborative targets.
• Cultivated a high-performance work environment focused on personal responsibility, and delivering high-quality results.

Operational Excellence & Efficiency:

• Spearheaded initiatives that achieved a 99.92% gate entry and GRN accuracy, and 99.75% gate exit accuracy within a 24-hour window.
• Executed 100% completion of same-day picking, and ensured 100% of deliveries were dispatched within 24 hours.
• Streamlined Goods in Transit (GIT) closures, consistently completing them within a 24-hour timeframe.
• Oversaw 30,100 unique storage locations (SPR: 7,000, Deep Dense: 5,000, Mezzanine: 18,100), optimizing storage density and accessibility.
• Achieved a transport on-time service level of 95%, and reduced customer complaints to a minimal 0.015%
• Managed vendor parts rejection management, maintaining an average rejection rate of only 3.2% against GRN lines.

Volume and Inventory Management:

• Directed high-volume receiving operations, handling an average of 1,300 truck unloads and 5,200 unique receipt lines monthly (totaling ₹140 crores in NDP value).
• Maximized inventory turnover ratio to 10 times per year across 14,300+ SKUs.
• Maintained an overall inventory stock value of ₹212 crores with optimized stock coverage (Parts: 42 days, Oil/Lubes: 21 days, Consumables: 13 days).
• Orchestrated a kitting business unit averaging ₹31 crores in monthly billing (23% of total), managing 450 SKUs, and packing 600,000 packets monthly.
• Administered significant packing operations, prepacking 4.7 million packets per month, including 1.8 million packets via semi-automatic lines.
• Delivered an average of 8,000 boxes to customers daily, with logistics freight costs performing efficiently at 2.03% of value.

Cross-functional Collaboration & Strategy:

• Collaborated directly with sales and marketing teams to align demand forecasting with promotional activities and new product launches.
• Provided critical demand insights to guide strategic decisions within new product development projects.
• Coordinated and consulted with cross-functional teams to ensure seamless operational continuity and alignment across the organization.
• Reported periodically to senior management (senior manager and deputy general manager), providing transparent updates on developments and key performance indicators.

Dispatch and Transportation Management

• Directed all dispatch shop floor activities, including categorizing shipments, ensuring proper storage norms, and optimizing the loading process according to strict SEW – Euro Drive SOPs and standards.
• Minimized shipment damages and elevated overall outbound quality control through rigorous pre-dispatch auditing of all packed cartons, based on daily schedules.
• Managed transporter Turn-In, Turn-Out (TITO) times, improving carrier efficiency, and streamlining yard operations.
• Spearheaded the transporter finalization process by receiving responses, compiling detailed comparison reports, and negotiating favorable terms.
• Executed comprehensive dispatch planning for PAN India operations, aligning logistics with specific customer requirements, and demand cycles.
• Coordinated seamlessly with the finance team on invoice generation and ensured all supporting documentation (online E-way bills, E-invoices) was provided to transporters, ensuring compliance.
• Guaranteed same-day dispatch for all invoiced materials by orchestrating efficient shop floor operations and cross-functional connectivity.
• Implemented robust tracking mechanisms to monitor shipments in transit until final delivery, and customer receipt.
  Reduced transit damage claims by analyzing error sources, implementing effective countermeasures, and streamlining the financial debit process for damages.
• Addressed and resolved issues with Online Service Support Providers (OSSP), as required, to mitigate bottlenecks and ensure seamless logistics flow.

• Conduct cycle count inventory processes to ensure accuracy and timely execution.
• Schedule categories for cycle count inventory and maintain strict records.
• Create an efficient space utilization plan
• Maintain adequate storage for warehouse and on-site inventory
• Alternate goods in inventory by observing first-in and first-out approaches to keep shelves organized and properly stocked.
• Train store staff in product dating and create procedures to eliminate loss.
• Stock count, variance analysis, and posting with necessary approval and root cause analysis.

• Unloaded packages from the truck, and stored them properly in the warehouse.
• Sort, organize, and store inventory in the proper location.
• Report damaged or missing part details to supervisors.
• Material tracking to run the production without stoppage.
• Maintained accurate records of the materials received and transported out of the warehouse.
• Submitted records to the supervisor.
• Attending the daily meeting, contacted by the unit manager.