Rajeev .
Bengaluru
Summary
Seasoned Senior Manager with 16+ years in the electrical equipment and heavy machinery manufacturing industries. Expert in leading teams to enhance production efficiency, reduce costs, and elevate product quality through Lean Manufacturing and continuous improvement practices. Committed to ensuring workplace safety and sustainability, with a proven ability to strategize and implement operational advancements.
Overview
17
17
years of professional experience
1
1
Certification
Work History
Factory Manager & Operational Excellence
Saft India Private Limited
Bengaluru
04.2023 - Current
- Oversaw production in a 63,500 sq. ft. factory, focusing on maximizing output while ensuring safety, quality, and cost-efficiency.
- Developed and executed strategic plans aligning with corporate goals and market needs.
- Compliance and safety management: Enforce strict compliance with the Indian Factories Act and other regulatory standards, including health and safety protocols, to create a safe and hygienic working environment as a factory manager.
- Directed projects using Lean Six Sigma to enhance plant performance.
- Team management: Supervise and mentor multiple team levels, workers' union, evaluate performance, and support a career mobility plan.
- Environmental Sustainability: Lead initiatives for energy savings and waste reduction, ensuring adherence to environmental regulations and corporate objectives.
Sr.Manager Operational Excellence & Industrial Pro
Saft India Private Limited
Bengaluru
04.2022 - 03.2023
- Develop, lead, and implement site-level Saft Excell system action plan by working closely with site management team.
- Lead and drive industrialization, Knowledge and Technology transfer and transformation projects as a project lead.
- Analyze the performance, assess the maturity level of the site, and propose improvement projects.
- Lead Improvement Projects utilizing standardized Lean Six Sigma tools and methods to improve plant performance.
- Develop GEMBA culture, performance management, and problem-solving culture at all site levels.
- Standardize lean processes and practices by training employees.
- Communicate and promote Lean practices and activities through various communication channels and networks within the company.
Manager, Operational Excellence & Industrial Pro
Saft India Private Limited
Bengaluru
04.2021 - 03.2022
- Lead and implement Saft Excellence System standards and road maps across the organization effectively.
- Manage industrialization projects as a project lead.
- Develop a lean network by setting up workshops, training, coaching, and support.
- Drive digitalization and automation projects as a project lead.
- Provide expert advice in defining new requirements and opportunities for applying efficient and effective solutions.
- Monitor and analyze various plant-level KPIs and performance.
- Partner with the site management team and ensure development of Site Steering Matrix consisting of the priorities and strategic projects for the site.
Deputy Manager, World Class
Saft India Private Limited
Bengaluru
04.2015 - 03.2021
- Work closely with the corporate operational excellence team and implement global policies.
- Facilitate and conduct training programs.
- Develop and implement an operational excellence auditing program based on corporate standards.
- Be proactive in looking for external good practices and share them with site teams.
- Connect with the Global manufacturing team to standardize processes and equipment.
- Facilitate site-level CAPEX by working closely with site management team.
- Develop and support daily performance management routine.
Manufacturing Engineer
Terex India Private Limited
Hosur
06.2011 - 04.2015
- Leading the efforts towards executing lean and Six Sigma projects for increasing process efficiency.
- Prepare plans for all NPI projects, coordinate with all stakeholders, and ensure effective execution of projects.
- Establish and document standard operating procedures, tools, jigs, and fixtures, ensuring that they satisfy the needs of the Manufacturing Facilities.
- Ensuring seamless coordination for carrying out ECOs and implementing as per timeline.
- Undertaking development of E-BOM and M-BOM, make and buy decision, assembly routing, and standard cost roll-up in ERP.
- Analyze and recommend improvements to all production processes and methods to facilitate cost reduction and quality improvement.
Production Engineer
Lincoln Helios India Limited
Bengaluru
10.2008 - 08.2009
- Supervised daily operations in the factory ensuring that all tasks are completed according to schedule.
- Coordinated with suppliers to ensure timely delivery of components required for assembly operations.
- Performed regular maintenance checks on machines used in the manufacturing process.
- Collaborated with cross-functional teams across departments like Design Engineering and Procurement.
Production Engineer
STI Sanoh India Limited
Bengaluru
05.2007 - 10.2008
- Distinguished efforts towards designing and developing work instructions and processes, as well as standardization, as per the Toyota Production System.
- Improved the production efficiency by implementing industry best practices, conducting process audits for identifying gaps, QMS/EMS internal auditing, and documentation.
- Undertook daily and weekly production planning, material, and resource planning. Entrusted with the responsibility of handling customer complaints.
Education
Master of Science - Engineering And Manufacturing Management
Coventry University U.K / MSRSAS
Bengaluru05-2011
Diploma - Mechanical Engineering
Rural Polytechnic
09-2004
Skills
- Lean Six Sigma
- Project Management
- Strategic Planning and Policy Deployment
- Leadership and Team management
- Operations Management
- Budget Administration
- Corporate Communications
- Industrial Safety
- Change Management
- Coaching & Training
- Methods and Industrial engineering
- Integrated Management System (ISO,EMS & OHSAS)
- Supply Chain & Warehouse Management
- Data-driven decision-making
Certification
- Lean Six Sigma Black Belt Certification (LSSBB) - Indian Statistical Institute
- Toyota Production System
- Volvo Production System
- Industrial Safety
Accomplishments
- Established efficient Daily Management Routine at all the levels of organization in Saft with digitized KPI tracking & actions.
- Managed transformation project at Saft, which resulted in 30% productivity improvement and saving of 25 M INR.
- Directed capacity planning initiatives, allowing for an 30% increase in production throughput without additional headcount.
- Successfully industrialized high speed continuous Nickel plating process at Saft as a project lead.
- Reconfigured 20,000 Sq-mt plant layout which improved work efficiency and reclaimed 2,000 Sq-mt area at Saft.
- Industrialized railway battery system manufacturing at Saft
Timeline
Factory Manager & Operational Excellence
Saft India Private Limited
04.2023 - Current
Sr.Manager Operational Excellence & Industrial Pro
Saft India Private Limited
04.2022 - 03.2023
Manager, Operational Excellence & Industrial Pro
Saft India Private Limited
04.2021 - 03.2022
Deputy Manager, World Class
Saft India Private Limited
04.2015 - 03.2021
Manufacturing Engineer
Terex India Private Limited
06.2011 - 04.2015
Production Engineer
Lincoln Helios India Limited
10.2008 - 08.2009
Production Engineer
STI Sanoh India Limited
05.2007 - 10.2008
- Lean Six Sigma Black Belt Certification (LSSBB) - Indian Statistical Institute
- Toyota Production System
- Volvo Production System
- Industrial Safety
Master of Science - Engineering And Manufacturing Management
Coventry University U.K / MSRSAS
Diploma - Mechanical Engineering
Rural Polytechnic
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