Summary
Overview
Work History
Education
Skills
Websites
Certification
Phone Numbers
Other Information
Personal Information
Affiliations
Accomplishments
Languages
Timeline
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NALLAPURAJU SUBHRAMANYA VARMA RAJU

NALLAPURAJU SUBHRAMANYA VARMA RAJU

Visakhapatnam

Summary

Plant Manager with extensive experience at Kuwait Recycling Ltd, specializing in manufacturing excellence through advanced ERP systems and continuous improvement methodologies. Demonstrated success in enhancing inventory control and achieving first-quality standards. Skilled in project management and client relations, contributing to operational success and high client satisfaction.

Overview

27
27
years of professional experience
1
1
Certification

Work History

Plant Manager & Manufacturing Consultant

Kuwait Recycling Ltd
05.2023 - Current
  • Responsible for Design & Deploy technology for Converting TDF(Tire shreds crumb rubber) into Pre treads / Fuel for cement etc industries/Artificial turf, Asphalt supplement, Moulded products
  • Responsible for technical feasibility study / Market trend / ROI planning & execution from RM sourcing to dispatch
  • Responsible for identifying opportunities for technology transfer / JV partners for Various products line

Senior General Manager Operations

Abatek (Asia) Public Limited company
12.2021 - 04.2023
  • Responsible for overall operations silicone rubber keypads, thermal pad, connectors, grommets, seals, rubber parts and various other input for automotive, medical, telecom, white goods and various other industries
  • Responsible for all operations from Raw material planning / sourcing to dispatch, inventory, sales forecast, QC testing etc
  • Lead Continuous improvement projects (Zero defect project / Operational control saving projects to meet budgeted targets)
  • Ensure annual budgets / stock counts/project & client management
  • Manage escalation from Europe/US /Asia clients & Global sales team
  • Lead SHE activities -Statutory compliance / Permit systems/compliance to OHSAS/EMS / Behavior safety.
  • Lead Manufacturing excellence systems deployments of Lean, TPM, 5S, Kaizen, OEE improvement, Lead time improvement in SCM, Migration from Legacy to ERP system, Cost loss analysis/Cost control

Planning and Manufacturing Excellence Head

QAFFE Qatar Ltd (of NAFFCO Group, DUBAI)
10.2018 - 12.2021
  • Provide direction for Manufacturing excellence programs: SMED, ECRS, PULL systems, Time & Motion study, 8D approach, 7 QC tools, Fish bone analysis, 5W1H Analysis for problem solving, Improve straight first quality & Customer satisfaction, Reduce Lead times.
  • Implementing Production planning & scheduling strategy for complete plant from Sales Order capturing to Dispatch schedules
  • Develop & Implement strategy for moving trading / servicing organisation towards manufacturing organisation
  • Manage inventory levels in line with Make to Stock & Make to Order manufacturing environment
  • MRP & MPS-Release Master production schedule based on MRP planning in ERP(Oracle 11I)
  • Capacity calculation and fixing factory capacity -based on time & motion studies
  • Implement advanced ERP modules-Advanced supply chain, Demand planning
  • Capacity enhancements / Ramp up plan based on customer demand through SMED, ECRS techniques etc
  • Assess Manufacturing, Procurement & Delivery Lead times to maintain budgeted inventory levels
  • Ensure stock rotation for ensuring FIFO system
  • Implement strategy to reduce inventory level by 20 million QAR
  • Capturing losses in process and implement actions to minimise/eliminate losses through PDCA, WhyWhy analysis etc
  • Ensure actions to attain KPI -Inventory target, Adherence to customer dispatch schedule

Operations Manager

TECHNO GLASS COMPANY
02.2016 - 01.2018
  • Responsible for all operations of Architectural & Automotive windshield manufacturing lines comprising of Glass pre-processing (cutting, breaking, grinding, screen printing, powdering) bending in Box furnace, Assembly with interlayer (PVB), Autoclaving followed by inspection and packaging
  • Experienced in Architectural glass processing on Brambilla, Bottero & North Glass cutting and tempering lines (Toughened) on Double glass/insulated glass processing-Shape cutting, holing, double edger, assembling with spacers, silicon application, tempering, Flat lamination
  • Experienced in all operations from Raw material planning to dispatch, inventory, sales forecast, QC testing etc
  • Ensure compliance to ISO 9001 2015 as MR
  • Ensure Internal /process and product audit periodically.
  • Involve and drive PPAP and new model developments.
  • Ensure risk analysis through PFMEA and implement control plan through PDCA to mitigate risks.
  • Ensure compliance to SOP, WI etc
  • Ensure implementation of continuous improvement activities and achievement of Objectives, KPI (OEE, COPQ, MTTR, MTBF etc)
  • Facilitate multiskilling of employees through competency skill matrix and assessment of training needs.
  • Facilitate Homologation audits for exporting to Europe (ECE), SASO
  • Facilitate training sessions from Team members to Executive level across functions in company
  • Ensure drafting annual training calendar through: Competency skill mapping, Training needs assessment, Pre/post training feedback & assessments, evaluation, MIS reporting

Manufacturing, EHS, IT Manager

Pilkington Auto Glass India (Pilkington plc, UK & NSG Group, Sumitomo Corporation JAPAN)
06.2008 - 02.2016
  • Lead Production, Engg, HR, EHS, SCM functions of Green field project
  • Facilitate Recruitment cycle-Screening, Shortlisting, Interview, Induction, Adoption etc
  • Ensure drafting annual training calendar through: Competency skill mapping, Training needs assessment, Pre/post training feedback & assessments, evaluation, MIS reporting
  • Involved in Executive development program in Manchester, UK
  • Trained at UK as TWI-JI Master trainer (Training within Industry) -to facilitate training on SOP, Competency skill mapping, Training content development for all functions, Training time management
  • Responsible for all operations of automotive windshield manufacturing line comprising of Glass pre-processing (cutting, breaking, grinding, screen printing, powdering) bending in Box furnace, Assembly with interlayer (PVB), Autoclaving followed by inspection and packaging
  • Have knowledge and experience in Float, Automotive glass processes like Automatic cutting lines (Bando, CNC, Hegla) etc, Silk screen printing, Silver grid printing, tempering and Sag (Box furnace) line bending, Assembly (interlayer) operations, Autoclaving (Teruzzi make) and trouble shooting, Final line inspections and defect control.
  • Coordination of various process improvement activities of all production lines by leading process improvers.
  • Ensuring inspections to avoid defect flow at various stages: In put inspection, Work in process & Final inspections.
  • Lead green book projects for improving Raw glass utilisation and other raw materials, consumables.
  • Facilitate OCS projects leading to various operational cost savings.
  • Ensure processing of claims related to customers and suppliers.
  • To achieve customer satisfaction in terms of Quality, Cost & Delivery.
  • Cost centre management.
  • Data accuracy in SAP and periodical stock counts.
  • Ensure compliance to ISO 9001 2008, TS 16949, 14001.
  • Facilitate multiskilling of employees through competency skill matrix and assessment of training needs.
  • Facilitate Homologation audits for exporting to Europe (ECE), China (CCC) etc.
  • Manufacturing excellence head for Facilitating improvements in Operations, Training effectiveness, Motivation, communication, Management of change, Visual improvement

Production & QC Incharge

MRF Tyres Ltd
02.1998 - 01.2008
  • Ensure production and QC activities as per SOP and within specification & as planned
  • Facilitate multiskilling of team members and supervisors
  • Mentor for new recruits in Communication, Time/Data management, Standard operating procedure
  • Ensure drafting annual training calendar through: Competency skill mapping, Training needs assessment, Pre/post training feedback & assessments, evaluation, MIS reporting

Education

Bachelor of Sciences -

ANDHRA UNIVERSITY
India

MBA -

PONDICHERY CENTRAL UNIVESITY
India

Skills

  • Manufacturing systems and ERP
  • HRMS and master data management
  • QHSE and LEAN practices
  • Supply chain management (SCM)
  • Production planning and scheduling
  • Budgeting and cash flow tracking
  • Expense control and overhead management
  • Inventory control and metrics improvement
  • First quality and product consistency
  • Continuous improvement methodologies
  • 8D problem-solving and FMEA analysis
  • Control plans and checklists
  • 7 QC tools application
  • Process capability (Cp, CPk) studies
  • Visual control techniques
  • Training needs assessment and planning
  • Project management and client relations

Certification

  • Certified Master trainer in TWI-JI, UK
  • CII (Confederation of Indian Industries) Certified Facilitator & Champion in Manufacturing excellence: Lean/TPM/5S/KAIZEN/TQM
  • Certified Auditor: ISO 9001 2015, ISO 14001, NEBOSH IGC for Occupational H&S, ISO/TS 16949

Phone Numbers

+91 8897567895, +91 9490431799

Other Information

None, Immediately available, English, Hindi, Arabic (Understanding)

Personal Information

  • Passport Expiry Date: Valid till 2026
  • Date of Birth: 12/15/74

Affiliations

  • Company representative for Environment and Safety at APSEZ, at Pilkington Glass, India
  • Team leader for the overseas training program in China and Malaysia for the Greenfield project at Pilkington Glass India
  • Team member in the campaign on WAGE WAR ON WASTE at MRF Tires India
  • Planning team lead in inventory reduction at QAFFCO, Qatar
  • Team lead for the Malaysia plant relocation to Thailand at Abatek Asia, Thailand Ltd
  • Group escalation contact for Europe and Asia at Abatek Asia, Thailand Ltd

Accomplishments

  • Group sustainability award winner (among 53 countries) at Pilkington Glass, India
  • CAPEX projects worth 20 million THB roll out within 6 months at Abatek Asia Thailand Ltd for capacity enhancements
  • SAP go-live is scheduled within two months of the Greenfield project rollout at Pilkington Glass, India
  • Record-breaking completion of probation within 2 months (target 4 months) at Abatek Asia, Thailand Ltd
  • Facilitated significant, straight, first-quality achievement (95% from 80%) within 1 month at Abatek Asia, Thailand Ltd
  • Significant RM inventory reduction of 20% at Abatek Asia, Thailand, Ltd
  • Facilitated significant employee engagement and employee turnover rate reduction through the 'ang pow' campaign at Abatek Asia Thailand Ltd

Languages

English
First Language

Timeline

Plant Manager & Manufacturing Consultant

Kuwait Recycling Ltd
05.2023 - Current

Senior General Manager Operations

Abatek (Asia) Public Limited company
12.2021 - 04.2023

Planning and Manufacturing Excellence Head

QAFFE Qatar Ltd (of NAFFCO Group, DUBAI)
10.2018 - 12.2021

Operations Manager

TECHNO GLASS COMPANY
02.2016 - 01.2018

Manufacturing, EHS, IT Manager

Pilkington Auto Glass India (Pilkington plc, UK & NSG Group, Sumitomo Corporation JAPAN)
06.2008 - 02.2016

Production & QC Incharge

MRF Tyres Ltd
02.1998 - 01.2008

Bachelor of Sciences -

ANDHRA UNIVERSITY

MBA -

PONDICHERY CENTRAL UNIVESITY

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NALLAPURAJU SUBHRAMANYA VARMA RAJU