RAHUL KUMAR
AHMEDABAD
Summary
Dynamic operations leader with a proven track record at Malcom Safety Pvt Ltd, driving productivity improvements and enhancing efficiency. Expert in production scheduling and team leadership, I successfully reduced lead times and inventory costs while fostering a culture of continuous improvement. Committed to achieving exceptional results through strategic decision-making and staff development.
Overview
17
17
years of professional experience
Work History
GM-Operations
Malcom safety pvt ltd
03.2025 - Current
- Managed production schedules, inventory control, and dispatch coordination.
- Directed safety and product department operations while supporting daily workflow needs.
- Analyzed profit and loss activity to identify trends and inform decision-making.
- Assessed employee performance and provided targeted feedback to enhance skills and address improvement areas.
Manager- Industrial Engineering & Product
SSAL-4 Shirting
02.2020 - 03.2025
- Product Development- Lead time reduced from 6-7 days to 3-4 days.
- Throughput time for bulk reduced from an average 48 hrs. to 4 hrs.
- Reduced WIP from 8000 to 700, lowering inventory carrying costs.
- Implemented strategies for productivity improvement across teams. -Weighted average of 12 from 10.4
- Improved efficiency by 2% through process optimization.
- Created concept of Plant in plant concept by creating VSM team for each line.
- Trained and created an I.E team with proper training for subordinates.
Manager Operations
SSAE PLC (Raymond)
06.2016 - 01.2020
- Set up 6 trouser production line and was able to achieve 6 productivities within 6-8 months of inception of each line.
- Established 4 jacket production lines to streamline manufacturing processes.
- Developed processes for transitioning cut materials to the warehouse for efficient storage.
- Created bin card process at sewing operators' machines where trims are being used. Decreased trim loss by a huge margin.
- Fostered a culture of serial number tracking for production, resulting in streamlined operations and faster purchase order closures.
- Built a self-sufficient team capable of decision-making and independent operations.
- Conducted training classes and assessments to develop skills.
- Served as the first member of Silver Spark, and started the recruitment of operators and engineers.
- Established a greenfield project, managing operations and initiating training in a new location.
Manager production & I.E
Arvind Good hills suit manufacturing ltd.
12.2015 - 05.2016
- Oversaw operations in the cut to pack process, managing the entire workflow and reducing inefficiencies.
- Achieved highest trouser production in February despite fewer working days.
- Reduced manpower in trouser section from 81 to 73, achieving 63% efficiency within 2 months.
Head of Operations.
Trends Apparel pvt ltd
Indore
07.2014 - 12.2015
- Oversaw response to a 1.6 times increase in production demand, aligning resources to meet targets.
- Coordinated outsourcing of 60,000 trousers to Arvind Goodhill within two months, optimizing supply chain.
- Led manufacturing unit for formal trousers production, ensuring quality and efficiency.
Production manager
Banswara Garments
Daman
07.2009 - 06.2014
- Took on responsibility for managing entire cut to pack operations.
- Implemented piece rate system in packing, where earlier 78 people used to pack 8000 pcs after implementation of UNI-Station, for each packer, the number of heads reduced to 34, thus saving 52 lacs annually.
- Created and merged piece rate calculation with Efficiency monitoring with barcodes (existing system) and reduced the 1.8 Rs per trouser thus saving 41 lakhs annually.
- Completed management trainee program, gaining experience in three units.
Education
B.F.Tech - Apparel Production
National Institute of Fashion Technology
Gandhinagar, Gujarat01-2009
Skills
- Production management
- Production scheduling
- Inventory control
- Dispatch coordination
- Operational analysis
- Operational efficiency
- Lean manufacturing
- Process improvement
- Quality control
- Workforce planning
- Team leadership
- Performance coaching
- Decision making
- Staff development
- Problem solving
Extra-Curricular Activities
Keen interest in Theatre and other literary activities.
People
- Has an eye on cost as well as on time delivery of goods.
- Managed a team of 3 floor in-charges and 13 line masters across 7 assembly lines.
- Extensive frontline experience in managing & motivating sewing operators.
- Liaised with key people in the local market to ensure labor availability to meet demand
Product
- Handled Suits for customers catering Raymond shops all over India and abroad
- Handled production orders from quantities ranging from 50 pieces to 1,00,000 pieces
- Worked with fabrics ranging such as PV, PVL, wool, cotton spandex.
- Managed products requiring processes such as washing over Dye, Denim Wash, handwork & Embroidery.
- Within a floor managed both Casual and formal setup.
Process
- Bore sole responsibility for entire cut, sew& pack operations for all the 6 lines of jacket and one vest, monthly 40k, 7.5k respectively with 700-800 machines.
- Delivering up to 550000 pieces/annum at SSAL and 10 lakh pieces Trousers/annum on 420 machines in Banswara.
- Drove subordinates to deliver required output in a specific Lead time and maintain cost budgets.
- Planned entire cut and sew production for multiple styles running simultaneously contingent on fabric, trims and accessories availability.
Graduation Project
- Arvind lifestyle shirting unit, Bangalore
- Worked on the subject “Reduction of D.H.U through S.Q.C Tools” and gained grassroots knowledge of the many dimensions of manufacturing in this industry.
Timeline
GM-Operations
Malcom safety pvt ltd
03.2025 - Current
Manager- Industrial Engineering & Product
SSAL-4 Shirting
02.2020 - 03.2025
Manager Operations
SSAE PLC (Raymond)
06.2016 - 01.2020
Manager production & I.E
Arvind Good hills suit manufacturing ltd.
12.2015 - 05.2016
Head of Operations.
Trends Apparel pvt ltd
07.2014 - 12.2015
Production manager
Banswara Garments
07.2009 - 06.2014
B.F.Tech - Apparel Production
National Institute of Fashion Technology