Karthikeyan Mohan

• Company Overview: Orthopedic medical devices and joint replacement.
• Responsible for overall warehouse operations across India.
• Accomplished with 50,000 sq. ft. facility handling 10,000 SKUs, with an inventory value of USD 35 million.
• Overseeing daily order processing and timely dispatches to meet customer and surgical demands.
• Coordinating the transfer of medical instrumentation kits required for surgeries across various locations.
• Monitoring and managing consignment stock movements between the warehouse, dealers, and hospitals.
• Handled sales returns from the market, and ensured timely issuance of credit notes.
• Achieved 100% inventory accuracy, with NIL variance, from March 2022 to March 2025.
• Achieved and sustained nil variance in consignment inventory across dealer, hospital, and warehouse locations from 2023 to 2025.
• Leading a team of 33 warehouse operators, 4 team leaders, and 1 logistics executive to ensure seamless operations.
• Manage all import and export operations for Zimmer, ensuring compliance with international trade regulations.
• Handle Customs Duty payments to facilitate timely clearance and delivery of shipments.
• Oversee the filing of Bills of Entry (BOE) in accordance with the Customs Tariff Act, applicable HSN codes, and relevant exemption notifications and scheme codes.
• Ensure accurate application of GST schedules and exemptions in the BOE checklist to comply with tax regulations.
• Monitor domestic shipment transactions closely to ensure efficient logistics operations.
• Delivered billing accuracy and timeliness within established cycles, strengthening cash flow, and sustaining customer satisfaction.

• Oversee raw material warehouse operations at the Nokia production plant, ensuring efficient storage, material handling, and seamless material flow to support uninterrupted production.
• Accountable for achieving and maintaining key warehouse KPIs, including inventory accuracy, order fulfillment, and space utilization.
• Ensure on-time delivery of materials and products, eliminating delays in supply chain processes.
• Maintain overall inventory accuracy, implementing robust stock control procedures.
• Managed 100,000 sq. ft. Warehouse containing 3,000 SKUs and inventory valued at €60 million.
• Directed quarterly wall-to-wall stock take activities, ensuring adherence to compliance standards, and accurate reporting.
• Lead a team of 120 warehouse operators and 8 team leaders, overseeing daily operational performance and workforce management.

• Managed overall warehouse operations, ensuring timely deliveries to production and customers, without line stoppages.
• Maintained RM (Raw Materials) and FG (Finished Goods) Days of Supply (DOS) levels to support uninterrupted operations.
• Monitored and achieved core KPIs across warehouse functions.
• Maintained and circulated MIS reports to all management levels.
• Oversaw warehouse and production, supermarket inventory accuracy.
• Ensured the achievement of daily, weekly, and monthly sales targets.
• Organized quarterly and annual factory stock takes to ensure inventory compliance.
• Finalized and negotiated contracts with scrap vendors while managing hazardous and non-hazardous scrap and waste.
• Conducted daily monitoring of scrap movement.
• Led and managed a large team of 170 operators and 10 team leaders.

Key Achievements:

• Transitioned operations from 3PL to in-house warehouse, resulting in annual cost savings of ₹6 million.
• Introduced a new packing method, achieving cost savings of ₹1.2 billion per year.
• Played a key role in recycling pallets and cartons from customers, delivering savings of ₹8.4 million annually.
• Awarded the “Catalyst Award” for innovative carton box implementation.
• Successfully implemented a Warehouse Management System (WMS) with barcode scanning in SAP, improving inventory accuracy and efficiency.

• Oversaw daily stock maintenance, ensuring inventory accuracy and compliance with KPI targets.
• Managed Days of Supply (DOS) and maintained quality inventory for managed parts.
• Maintained detailed records of scrap and damaged goods within the warehouse.
• Directed operations for a 140,000 sq. ft. warehouse with 3,500 SKUs and inventory worth €79 million.
• Handled 89 VMI-mode suppliers, ensuring timely resolution of queries and supply coordination.
• Monitored daily cycle counts and rack validation, while training operators to minimize picking and putaway errors.
• Reported material variances to top management and suppliers, along with root cause analysis.
• Managed a large team of 200 operators, 8 team leaders, and 2 supervisors per shift.
• Coordinated with the Nokia LSP team to ensure uninterrupted supply to the production line.
• Directed inbound shipments, inventory management, outbound dispatches, space planning, packaging, and warehouse documentation.
• Oversaw utilization and maintenance of Material Handling Equipment (MHEs).
• Planned and executed line replenishment activities to prevent production stoppages.
• Implemented LEAN practices, organized 5S, Kaizen, and HSE training, while capturing operator feedback for process improvement.
• Regularly updated management with monthly LEAN efficiency reports and shift-wise performance tracking.
• Conducted training sessions for team members based on job requirements to build skill sets and enhance efficiency.

Key Achievements:

• Core team member of CEVA I-Hub and instrumental in implementing LEAN practices.
• Achieved India’s first BASIC site in LEAN certification, driving operational excellence.
• Strengthened inventory accuracy and reduced errors through effective cycle count and operator training programs.
• Enhanced site efficiency and productivity through structured performance monitoring and LEAN initiatives.

• Managed end-to-end warehouse operations across multiple Bangalore locations, covering 100,000 sq. ft. of storage space.
• Oversaw daily inbound, outbound, and inventory management while ensuring compliance with customer requirements and business policies.
• Led manpower planning for new projects and managed a team of 8 executives and 30 handlers.
• Conducted regular stock audits and process audits across Gati warehouses, driving stock accuracy and operational control.
• Submitted detailed warehouse stock reports to management and ensured timely closure of non-conformances through corrective and preventive measures.
• Conducted training programs for warehouse staff on WMS, operations processes, and compliance standards.
• Performed audits and surprise checks to strengthen warehouse discipline and operational control.
• Ensured that warehouse logistics processes aligned with both business policies and customer expectations.

Key Contributions:

• Improved stock accuracy and audit compliance across warehouses.
• Strengthened operational efficiency by implementing structured staff training and process improvements.
• Enhanced control mechanisms through surprise audits and root cause corrective actions, reducing inventory variances.

• Ensured timely availability of input materials for production lines to prevent downtime.
• Implemented inventory control measures by defining and monitoring stock and reorder levels.
• Reduced material damage through preventive handling practices and coordinated return-to-supplier processes.
• Initiated and managed scrap and waste disposal activities in line with company guidelines.
• Directed day-to-day operations, including customer service, coordination with service providers, invoicing, documentation handling, and MIS reporting.
• Monitored KPIs to align with company performance norms and ensure operational efficiency.
• Conducted regular training sessions for warehouse staff on processes, compliance, and best practices.
• Supervised 4 Team Leaders, 80 Warehouse Operators, and 5 Data Entry Operators, ensuring smooth workflow and productivity.

Key Contributions:

• Supported the Nokia iHub Project, playing a critical role in supply chain operations during peak demand.
• Strengthened warehouse accuracy by reducing damages, and implementing tighter inventory control.
• Improved team productivity and compliance through structured training programs and performance monitoring.

• Analyzed and planned container pulling from port to warehouse, ensuring timely material availability.
• Led planned cycle counts with the client to correct inventory discrepancies and improve stock accuracy.
• Served as a core member during warehouse startup, establishing and implementing logistics procedures for GM spare parts operations.
• Managed daily receipt and confirmation of consignments from multiple GM platforms (US, Australia, Canada, Korea).
• Maintained accurate documentation of scrap and damaged parts within the warehouse.
• Processed invoices in SAP for both stock and VIP orders.
• Developed expertise in PROLOGS (DHL in-house WMS) covering inbound and outbound operations such as receiving, put-away, picking, and shipping.
• Assisted in testing and upgrading versions of PROLOGS to enhance system efficiency.
• Supported the Inbound Supervisor by managing a team of 21 warehouse operatives, ensuring smooth daily operations.

Key Achievements:

• Promoted from Administration Assistant to Team Leader within 18 months, showcasing rapid career progression.