Minitab
Jay Kotak
Summary
Adept at spearheading supply chain efficiencies, I led a strategic initiative at Kellogg's Tolaram SA, saving $250,000 annually. With expertise in Lean manufacturing and Six Sigma methodologies, I excel in optimizing operations and mentoring teams. My multi-plant experience and strong supplier relationship management skills drive substantial improvements in production scheduling and warehouse operations.
Overview
5
5
years of professional experience
1
1
Certification
Work History
Supply Chain Manager
Kellogg's Tolaram SA
02.2022 - 06.2023
- Spearheaded the transition to a new 3PL partner for outbound logistics, managing the entire process from RFP collection to contract signing. Conducted comprehensive vendor evaluations and cost comparisons, securing board approval for the change. This strategic initiative resulted in annual cost savings of $250,000, significantly improving the company's P&L performance.
- Collaborated with corporate commodity team to secure optimal pricing for key ingredients like hard wheat flour and cooking oil, based on global market trends.
- Monitored and tracked supplier performance to enforce adherence to quality standards and established timelines.
- Optimized inventory management by implementing actionable improvements to increase replenishment efficiency, reduce downtime, and maintain optimal stock levels, resulting in maximized inventory turnover.
- Teamed with sales and marketing teams to confirm that product availability meets customer demand.
SAP Business Champion
De United Foods Limited
04.2021 - 02.2022
- Responsible to implement Extended Warehouse Management module across 14 BUs, consisting of backward integrated businesses- Instant Noodles,Flour Mills, Edible Oil Refinery and Flexible Packaging.
- Collaborated with upper management to drive strategy and implement new processes.
- Oversaw document development across project workstreams to create internal control statements per compliance and regulatory standards.
- Communicated and explained business requirements to team members to understand and implement functional demands.
Continuous Improvement Manager
Raffles Oil LFTZ Enterprise
09.2020 - 04.2021
- Managed development and implementation of lean and continuous improvement manufacturing initiatives across production environment.
- Created Spare Parts Consumption and Spares Aging reports, enhancing visibility into the spares budget and enabling more effective weekly planning of spares consumption.
- Monitored Six Sigma project control charts monthly and provided reports to the Factory Manager and Corporate Six Sigma Head.
- Developed and implemented Lean production training programs, while mentoring Six Sigma Green Belts in continuous improvement and lean manufacturing processes.
- Initiated IoT implementation by collecting technical specifications for equipment across refinery, fractionation, and packaging lines, and engaged with potential vendors for solutions.
Continuous Improvement Manager
De United Foods Industries (Ghana) Limited
10.2019 - 09.2020
- Restructured the production reporting system and built a dedicated production planning and inventory team to enhance operational efficiency and streamline processes.
- Analyzed and presented comprehensive operational data across production, quality, engineering, and warehouse departments to senior management on a quarterly basis, driving informed decision-making and operational improvements.
- Utilized value stream mapping to plan raw material flow and optimize daily warehouse structure, while leading the lean team in executing a 5S drive across the production hall and warehouse, improving organization and efficiency.
- Developed and implemented a downtime categorization report, uncovering hidden inefficiencies across all departments and driving targeted improvements.
- Championed the "New Normal" drive across the factory during COVID-19, ensuring smooth operations and adherence to safety protocols.
- Mentored and coached 22 plant operatives on the Lean Six Sigma Yellow belt and continuous improvement approach.
Six Sigma Coordinator (Black Belt)
De United Foods Industries Limited
09.2018 - 10.2019
- Trained 20 plant operatives in Lean Six Sigma Yellow Belt methodology, enhancing process improvement skills across production, engineering, and warehouse departments.
- Led 5S activities across daily warehouses and the spare parts store, improving organization, efficiency, and workplace safety.
- Developed a weight variance report for the quality assurance team and trained the on-line team in its implementation, enhancing quality control measures.
Education
Bachelor of Technology - Mechanical Engineering
Vellore Institute of Technology
Vellore, India04.2018
HSC - 12th Grade -
Airport School
Ahmedabad, IndiaSkills
- Multi-plant experience
- Supply Chain Management
- Warehouse Operations
- Supply chain distribution
- Lean manufacturing principles
- Six Sigma Methodologies
- Supplier Relationship Management
- Production Scheduling
Projects
Lean Six Sigma Project: Reduction of Leakages in Oil Pillow Pack SKU
- Resolved excessive oil leakage in pillow packs, impacting product quality and customer satisfaction. Conducted root cause analysis and optimized packaging line processes, resulting in a 42% reduction in leakages and improved product integrity.
Lean Six Sigma Project: Reduction of weight variance in 1L Oil Pillow Pack SKU
- Addressed weight inconsistencies in 1 L oil SKUs causing unpredictable variances. Applied targeted process improvements based on root cause analysis, leading to a 57% enhancement in sigma level and more consistent product weight across batches.
Lean Six Sigma Project: Reduction of weight variance in Instant Noodles in 70g and 120g SKU
- Addressed overweight and underweight products affecting Flour and Oil Variance monthly. Implemented DMAIC methodology to optimize line settings, achieving a 10% improvement in sigma level and enhancing Critical to Quality (CTQ) metrics.
Lean Six Sigma Project: Reduction of Scrap generation from 3.85% to 2.8% on Instant Noodles Line.
- Addressed a 3.85% scrap rate on the noodles line, leading to $30,000 in annual losses. Applied DMAIC methodology and hypothesis testing on critical parameters, resulting in a 27% reduction in scrap generation, improving cost metrics, and saving $30,000 annually.
Lean Six Sigma Project: Reduction of Batch variation due to Silo Scale.
- Tackled batch variation causing recipe adherence issues and supply-consumption discrepancies. Applied DMAIC methodology and hypothesis testing on critical parameters, reducing variation from 1.86% to 0.42%, resulting in a 77% improvement in batch consistency.
Certification
- Lean Six Sigma Green Belt, Exemplar Global - 2018
- Lean Six Sigma Black Belt, Exemplar Global - 2018
- Design for Six Sigma (DFSS) Black Belt,Exemplar Global -2021
- Business Sustainability Management, Cambridge Institute for Sustainability Management - 2023
Software
Microsoft Office
Timeline
Supply Chain Manager
Kellogg's Tolaram SA
02.2022 - 06.2023
SAP Business Champion
De United Foods Limited
04.2021 - 02.2022
Continuous Improvement Manager
Raffles Oil LFTZ Enterprise
09.2020 - 04.2021
Continuous Improvement Manager
De United Foods Industries (Ghana) Limited
10.2019 - 09.2020
Six Sigma Coordinator (Black Belt)
De United Foods Industries Limited
09.2018 - 10.2019
Bachelor of Technology - Mechanical Engineering
Vellore Institute of Technology
HSC - 12th Grade -
Airport School
- Lean Six Sigma Green Belt, Exemplar Global - 2018
- Lean Six Sigma Black Belt, Exemplar Global - 2018
- Design for Six Sigma (DFSS) Black Belt,Exemplar Global -2021
- Business Sustainability Management, Cambridge Institute for Sustainability Management - 2023
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