Hi, I’m
Krishnan K
Chennai
Summary
Results-driven manufacturing and operations leader with over 19 years of proven expertise in electronics assembly (SMT& FATP, PCBA), mobile LCD integration, 3G/4G network technologies, and automotive manufacturing including EV BS6 vehicles and remote-controlled 4-wheel defense vehicles. Skilled in end-to-end production planning (short- and long-term), cost estimation, lean manufacturing, and cross-functional team leadership. Adept at implementing Lean Six Sigma methodologies to streamline processes, eliminate waste, and drive continuous improvement. A high-performing, self-driven professional recognized for managing complex projects and improving operational efficiency. Committed to maintaining a strong safety culture with zero safety incidents, consistently achieving zero customer complaints through strategic resource management, and excelling at building and mentoring high-performing teams to deliver consistent results under pressure and meet business goals.
Overview
19
years of professional experience
3
Certificate
Work History
TVS Sundaram Industries Pvt. Ltd.
Operations Manager
02.2024 - Current
Job overview
- Develop and implement short- and long-term production strategies in collaboration with the S&OP team to align customer demand with capacity planning.
- Lead annual Capex planning and cost estimation reviews with Finance to align project costs with budgetary goals.
- Manage end-to-end plant operations and ensure on-time delivery, high product quality, and customer satisfaction.
- Optimize resource allocation and asset utilization to meet target DLU & DLE.
- Increase throughput and asset capacity while maintaining strict control over operational costs and quality standards.
- Maintained accurate inventory levels and achieved 100% on-time delivery with zero customer complaints.
- Build a high-performance culture by mentoring staff, aligning individual goals with KPIs.
- Analyze production data to identify bottlenecks, reduce overtime, and enhance overall operational efficiency.
- Monitor plant performance proactively and implement corrective actions to meet operational targets.
- Collaborate with the SCM team to assess new vendors and drive material cost optimization strategies.
- Maintain consistent product quality through rigorous inspections and quality control protocols.
- Led recruitment, training, and employee development programs, building CFT and improving workforce capabilities.
- Execute Lean manufacturing strategies to improve production flow, eliminate waste, and boost plant performance.
- Achieved zero safety incidents by enforcing strict safety protocols, strengthening compliance culture.
Flex India Pvt. Ltd.
Production Manager
05.2021 - 02.2024
Job overview
- Managed the entire production lifecycle, from planning to delivery, ensuring quality compliance.
- Implemented strategies to improve SMT OEE from 73% to 79%, reducing model changeover and increasing throughput.
- Consistently maintained 100% schedule and model adherence through daily production tracking.
- Implemented preventive and predictive maintenance schedules to boost equipment uptime & reliability.
- Assessed the performance of sub-team managers through KPIs, providing feedback and guidance for improvement.
- Successfully managed inventory accuracy, maintaining optimal stock levels while minimizing excess.
- Collaborated with an engineering team to support the smooth introduction of new STB products into production.
- Led Six Sigma projects that delivered long-term productivity improvements and generated overall cost savings of $30K.
- Motivated people and formed various quality circles and achieved the people excellence award.
- Led ownership of end-to-end scrap reduction from 0.3% to 0.17%.
BorgWarner cooling system India Pvt. Ltd.
Production assistant Manager
10.2018 - 04.2021
Job overview
- Aligned delivery schedules with sales orders, material availability, and capacity to ensure 100% on-time delivery.
- Integrated short- and long-term production plans with the Planning team to improve agility and efficiency.
- Led Tier 2 CFT meetings, driving accountability and tracking plant KPI achievements.
- Monitored daily production performance, proactively optimizing processes and reallocating resources to reduce downtime.
- Successfully launched BS6 vehicle actuators and drive units, increasing production output from 750 to 826 units.
- Maintained layer process audit scores exceeding 95% consistently, ensuring high-quality production processes.
- Improved MOLD M/C OEE from 72% to 80% by implementing the SMED significantly reducing mold changeover time.
- Being a 5S & KAIZEN leader for entire plant and achieved best score across zone leader.
- Certified Internal Auditor for ISO 14001:2015 and ISO 45001:2018.
- Achieved zero safety incidents over a full year through strong compliance.
Nokia Network India Pvt. Ltd.
Operation Team leader
04.2011 - 09.2018
Job overview
- Developed and executed weekly and monthly production plans based on customer demand.
- Monitored production performance daily, adjusted resources and processes to drive cost reductions and improved efficiency.
- Achieved the highest filter production output per day 1200 units by implementing multiskilled operations and line balancing.
- Improved work order closure rates 98% by addressing ageing orders through periodic audits and coordinated CFT team.
- Analyzed customer complaints and prepared corrective action reports to drive products quality improvements.
- Utilized SAP and PLCM applications for accurate inventory maintenance and process control.
- Achieved €250K in cost savings and ₹12 lakh in overall Kaizen savings through Lean and process optimization.
- Played a leader role in implementing Kaizen, Poka-Yoke, cycle time reduction, line balancing.
- Led a Six Sigma Green Belt project that improved filter productivity by 20% through process yield improvements.
Wintek India Pvt. Ltd.
Production Engineer
06.2008 - 04.2011
Job overview
- Led daily production planning and manpower allocation to ensure smooth operations and resource optimization.
- Improved product quality by reducing LCD rework from 1.2% to 0.1% through lean process optimization.
- Achieved 99% inventory accuracy by combining MES integration with systematic periodic internal audits.
- Achieved model and schedule adherence 100% without Quality impact.
- Escalated critical production issues, ensuring swift resolution and minimal disruption.
Nestronics India Pvt. Ltd.
Production assistant Engineer
05.2006 - 06.2008
Job overview
- Operated SMT, wave soldering, assembly and test equipment.
- Improved manpower utilization from 89% to 98% through effective resource planning.
- Achieved production target 98% and improved yield rate from 92% to 99% through process improvement.
- Performed changeovers and maintained 5s standards.
Education
Anna University
B.E. from Electronics & Communication Engineering
04.2006
University Overview
GPA: First Class
Skills
- Project management
- Production and operations management
- Process improvement
- Lean manufacturing
- Performance management
- KPI execution
- Team leadership
- People development
- Resource optimization
- Quality assurance
- Continuous improvement
- Safety compliance
- SAP PP and MM
- Microsoft Office proficiency
- Internet applications expertise
- Single-minute exchange of die (SMED)
- Value stream mapping (VSM)
- Overall equipment effectiveness (OEE)
- Root cause analysis
- 8D problem-solving methodology
- Quality control tools
Timeline
Operations Manager
TVS Sundaram Industries Pvt. Ltd.
02.2024 - Current
Production Manager
Flex India Pvt. Ltd.
05.2021 - 02.2024
Production assistant Manager
BorgWarner cooling system India Pvt. Ltd.
10.2018 - 04.2021
Operation Team leader
Nokia Network India Pvt. Ltd.
04.2011 - 09.2018
Production Engineer
Wintek India Pvt. Ltd.
06.2008 - 04.2011
Production assistant Engineer
Nestronics India Pvt. Ltd.
05.2006 - 06.2008
Anna University
B.E. from Electronics & Communication Engineering
Affiliations
· Coordinator of filter line development to achieve in-house filter productivity improvement.
· New product development training undergone in Finland (OULU)
· Quality project coordinator of the filter line.
· Certification done for people excellence management.
Accomplishments
🏆 Six Sigma Green Belt - Nokia Siemens & Flex company
🏆 Awarded Quality Project Runner-Up – IOQ (2013, 2016)
🏆 Member of the Kaizen promotion officer for three years.
🏆 Honored with the best KPO Award - 2012, 2017 & 2018.
🏆 Honored with Production Excellence Award for Outstanding Performance (Nokia-2012, Borgwarner-2019)
🏆 Received numerous letters of appreciation from the production head.
🏆 Honored with best 5s zone leader- 2018,2019.
🏆 Certified internal auditor for ISO14001:2015 / ISO45001:2018.
🏆 Zero Safety Incidents – 2020 (Core EHS-GSSF Team Member).
🏆 Successfully managed largest team: 850 DL + 20 IDL.
Certification
- Six Sigma Green Belt - Nokia Siemens & Flex company
- Certified internal auditor for ISO14001:2015 / ISO45001:2018
Personal Information
- Total Experience: 20 years
- Passport Number: R3747246
Initiatives And Leaderships
- Coordinator of filter line development to achieve in-house filter productivity improvement.
- New product development training undergone in Finland (OULU)
- Quality project coordinator of the filter line.
- Value stream mapping (VSM) is implemented to reduce product change over time.
- Certification done for people excellence management.
Lean Projects
- Implemented Mixed Model Line concept using Lean principles, significantly improving flexibility.
- Reduced production space requirements by 50.2% (from 1220 sq. m to 607 sq. m) through layout optimization.
- Applied kitting processes to reduce changeover time and increase operational efficiency.
- Led RFID tool tracking implementation for screwdrivers to enhance traceability and reduce downtime.
- Reduced mold changeover time using SMED.
- Introduced Layer Process Audits to improve process control and compliance.
- Airtel STB productivity improvement from 180 to 240 UPH.
Personal Information
- Total Experience: 20 years
- Passport Number: R3747246
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