RAHUL R
Kasargod,KERALA
Summary
Strategic Plant Head with 7+ years of progressive leadership experience in large-scale PU footwear manufacturing. Currently leading a 24-hour manufacturing facility with 8 million pairs annual production capacity and ₹170 crore turnover. Accountable for full P&L ownership, operational excellence, cost transformation, and cross-functional team leadership. Proven ability to scale operations, demand & supply chain planning, optimize resources, drive continuous improvement initiatives, and deliver measurable bottom-line impact.
Overview
6
6
years of professional experience
Work History
PLANT MANAGER
WALKAROO INTERNATIONAL PVT LTD
Delhi
09.2024 - Current
- Managed direction and planning for 24 hours plant (one lakh SQFT) with focus on optimization of daily functions, exceeding customer expectations, and achieving KPIs.
- Responsible for P & L statement and review of the manufacturing unit which has a capacity for producing 8 million pairs and an annual turnover of 170 crore.
- Developments of Sop’s, drive continuous improvement, Data driven operations and real time decision making.
- Reduced costs by eliminating materials waste and unnecessary labor hours.
- Maximized plant safety through proactive strategies and well-structured training.
- Led, trained and coached plant staff to facilitate high levels of productivity and quality.
- Maintained quality of product with robust inspections and assessment team.
- Negotiated favorable contracts with suppliers, securing cost savings on raw materials without sacrificing quality.
- Established positive relationships with suppliers to obtain timely deliveries of materials and products.
- Monitored inventory levels and restocking schedules to avoid production delays from unavailable materials.
- Utilized lean manufacturing and six sigma methodologies to improve operations Increasing product profitability by value engineering activities.
- Led cross functional operations across production, supply chain, quality, purchase and inventory management, maintenance and HR.
- Facilitated daily Tier 1 Integrated Product Team (IPT) meeting with direct support team, followed by brief effective presentation of daily metrics at Tier 2 meeting held between Factory Managers and Director of Operations.
- Manage CAPEX portfolio and investment plan for sustenance as well as expansion projects.
- Managed budgeting and resource allocation, ensuring optimal use of funds for operational efficiency.
- Collaborated with sales team to align plant capabilities with customer demands, fostering long-term business relationships.
PRODUCTION MANAGER
WALKAROO INTERNATIONAL PVT LTD
Delhi
02.2023 - 09.2024
- Managed continuous improvement initiatives to drive gains in quality, flow, and output.
- Planned and scheduled customer orders based on materials availability, machine capacity and constraints for production; During tenure production helped increase by 65%.
- Analyzing sales plan and variation, then preparing monthly production plan and planning accordingly to achieve more sales than previous month.
- Handled customer complaints including physically visiting customer plants and collaborating with team to identify and solve issues thus reducing customer complaints by 35% during tenure.
- Handled all SAP PP works-BOM, Routing, planning, stock monitoring.
- Problem solving using various methods like FMEA, Fish bone analysis, analysis and Lean tools.
- Well versed with Make to Stock, Make to Order and Engineered to Order environments in Footwear Industry. (Discrete industry).
- Monitoring and evaluating all manufacturing processes to increase efficiency and reduce costs as much as possible.
- Team development by continuously evaluating work and reviewing team members and identifying all issues in team and providing continuous support to all members according to operating standards.
- Ensure employees full understanding of business needs, auditing compliance, tracking progress towards goals and measuring analytics on P&L and ROI.
- Reviewed maintenance and repair problems to determine appropriate action for resolution.
- Evaluated Production data to plan metrics, make strategic changes towards training and operational standards to drive teams’ success in established business plan goals.
- Expertise SAP PP module-have an experience in creating master data, MRP, BOMs, routings, work centers/ resources, Production versions, planning, optimization, production orders, and confirmation.
- Utilized data analysis tools to identify and resolve production issues.
Executive-Production Planning and inventory control
WALKAROO INTERNATIONAL PVT LTD
Delhi
01.2020 - 02.2023
- Organizing daily production based on market projections, guaranteeing timely and regular delivery of completed goods, and facilitating improved supplier communication for the acquisition of raw materials.
- Directed the efforts of up to 400+ personnel to maintain and safeguard 1.2 billion in assets.
- Strategically planned and optimized labor resources and budgetary funds that meet customer needs and deliver high quality services.
- Business requirement analysis, mapping the company requirement to standard sap process, “AS-IS”, “TO BE” analysis.
- Troubleshooting system issues, analyzing processes, recommending courses of action.
- Lower manufacturing costs through accurate estimation, enhanced productivity, and target-based stock inventory control.
- Carry out weekly reviews, DRM, and upper management presentations of important metrics.
- Effectively organized company data using Microsoft Excel, doing data analysis with pivot charts and diagrams, and automating repetitive tasks with VBA macro file.
Education
BACHELOR OF TECHNOLOGY - MECHANICAL ENGINEERING
Amal Jyothi College of Engineering
06.2019
Skills
- RCA and problem solving
- Make to Stock
- Make to Order
- Engineered to Order
- SAP PP Module
- Cost Control & Budgeting
- Team Leadership & Development
- Proficient in Microsoft office
- Production Planning & Inventory Management
- Data Analysis & Operational Excellence
Accomplishments
- Developed and implemented Shop Floor Automation Tool for production scheduling.
- Reduced PU scrap by 60% using varnish method, saving 20 lakhs annually.
- Utilized dead stock material worth 15 lakhs through process modification.
- Reduced packing conveyor manpower by 3 per shift, saving 11 lakhs annually.
Personal Information
Title: Operations Manager-Plant Head
Disclaimer
I hereby declare that all the information furnished above is true to the best of my knowledge.
Timeline
PLANT MANAGER
WALKAROO INTERNATIONAL PVT LTD
09.2024 - Current
PRODUCTION MANAGER
WALKAROO INTERNATIONAL PVT LTD
02.2023 - 09.2024
Executive-Production Planning and inventory control
WALKAROO INTERNATIONAL PVT LTD
01.2020 - 02.2023
BACHELOR OF TECHNOLOGY - MECHANICAL ENGINEERING
Amal Jyothi College of Engineering