Jamal Mohamed KAKKADAVATH

I am entrusted with overseeing the end-to-end operations of 7 external manufacturing facilities dedicated to the Functional Nutrition and biscuit portfolio. In my role, I anchor the technology and cost negotiations within the contract manufacturing unit, simultaneously overseeing safety, quality, and compliance aspects of the CM units. This dynamic role involves managing an annual spend of 110 Crore, with a primary focus on long-term capacity planning and sourcing strategies to ensure the seamless production and delivery of high-quality products.

• Successfully executed a network rejig by establishing two new manufacturing facilities and strategically phasing out two older factories with zero supply disruption
• Improved service levels by 500 bps and FG DOH by 3 days, enhancing customer satisfaction and contributing to a more responsive and agile supply chain
• Implemented strategic changes resulting in 8% hard cash savings for consecutive 2 years, contributing to improved profitability and cost-effectiveness
• Spearheading the strategic transformation of 50% manpower reduction in CM network. This initiative will deliver a substantial 20% reduction in overall costs within the next two years.

As the Factory Operations Manager for the largest contract manufacturing unit in South India with an annual volume of 30KT, I had to oversee the end-to-end aspects of factory cost, product quality, operations and service for the unit

• Overall, 5% hard cash savings at site for consecutive 3 years of 2018-20
• Led the successful implementation of SAP for the entire 3P team, ensuring timely execution with zero sales loss and minimal operational downtime
• Installed Sachet (7KT) and Pouch (10KT) line capacity within a swift three-month timeframe
• In 2019, successfully improved Jar line efficiency with a 500 bps increase in OEE.

In the role I had to manage 3 external sites for Health food drinks and toothpaste. I was responsible for the effective planning and sourcing of packing materials, raw materials, consumables, and the dispatch of finished goods to sales depots, ensuring alignment with market requirements. Additionally, I played a vital role in coordinating with procurement, central quality, NPI and R&D teams, as well as engaging with business partners for product re-launches, trials, and various cost-saving initiatives

• Achieved a record-breaking manufacturing volume of 85 KT at the Baddi cluster in 2014-15, maximizing EEZ benefits for the company
• Executed the strategic shutdown of the Sensodyne toothpaste manufacturing site at Baddi, seamlessly consolidated the volume to Silvassa Unit
• Successfully improved plant Overall Equipment Effectiveness (OEE) by 200 basis points, incorporating the gains into conversion costs, and reduced overall manpower through strategic value stream mapping initiatives.

My role was to consolidate and standardize Process Excellence initiatives within the cluster, driving continuous improvement both quantitatively and qualitatively to enhance costs, quality, and service. Additionally, I was leading training, implementing methodologies such as TPM, 6 Sigma, 5S, Lean, Kaizen, and others

• Led the successful launch of Total Productive Maintenance (TPM) initiatives at three factories and 20+ external sites along with implementation of comprehensive review system
• Circle Team (CT) initiatives for shop floor teams to foster continuous improvement and drive operational efficiencies.

I held overall responsibility for the factory with a team strength of 35 staff members and 350 workmen. Additionally, I handled external liaison with statutory bodies, manage the factory staff appraisals and labor wage revision. My responsibilities also extended to capacity planning, factory budgeting, and meticulous management of material and operational costs (COGS) against the budget

• Successfully led the transition and stabilization of Hair Code factory and supply chain operations in Egypt post-acquisition of the Brand
• Achieved a significant capacity enhancement of the Hair code factory by doubling the capacity within a year through productivity improvement
• Successfully navigated three labour wage revision processes for both factories in challenging conditions
• Managed the shutdown of a Fiancée factory with over 300 manpower and orchestrated the seamless relocation of operations to a greenfield project
• Established infrastructure and systems at new green field facility to clear GMP audit by the Egyptian Ministry of Health.

Ensuring quality control and assurance throughout the Factory, Refineries, Subcontract Operations, and BM/IM vendors, while also spearheading the implementation of a Manufacturing Excellence Model across the entire factory

• Established quality systems for a 500 KL monthly capacity Contract Manufacturing and Packing Unit
• Achieved a remarkable 70% reduction in customer complaints within a span of 6 months
• Accredited Marico Manufacturing Excellence certification for the Kanjikode plant while leading Plant Quality Assurance.

Leading end-to-end subcontract operations from raw material receipt to finished goods dispatch, while also coordinating with the Central Planner to ensure efficient servicing of depots. Also ensure the site cost within budget and execute savings plan

• Successfully doubled the capacity of subcontract operations from 500 KL/month to 1000 KL/month
• Achieved a significant reduction in laminate loss, decreasing from 5000 ppm to 500 ppm
• Implemented new technology of multi-lane packaging in oil sachet
• Executed a project aimed at reducing filling weight variation through the implementation of Statistical Process Control (SPC) tools.

Joined as a graduate apprentice trainee, actively contributing to the shop floor team involved in CNC machining of motorbike crankcases and machine assembly

• Hands-on experience in CNC Machine operation.