Sahaya Milton Johnrose

Leading a team of 2 Engineers & 12 packers for managing entire product projects and packaging cost saving projects

• Developed new packing concepts for Vietnam, Malaysia, Kenya, South African and Indonesia (overall sixteen variants)
• Coordinate with overseas customers to resolve pilot packing issues
• Interacted with inspection department to address and resolve packaging issues
• Developed packaging process to improve productivity and meeting daily requirements
• Support to production & CFT for achieving common goal and handling day to day operation issues
• Streamlined packing process at CKD line by developing PPS (packaging process sheet) to ensure 100% packaging instruction adherence
• Estimated costs for new business with effective packing solutions based on customer requirements
• Identified areas for business improvements and utilized client feedback to drive developments

Achievements:

• Achieved 25 % cost saving per truck by converting Metal packing to corrugation and wood packing solutions
• Improved lot size of 6 unit to 12 unit with customer approval to provide container utilization which gave up to One 40' HC per per lotsavings in container

Managed team of 4 company employees and 8 contract employees, overseeing training, and professional growth of employees

Role in External packaging

• Coordination with supplier to implement proposed packaging concept for new launch programs
• Ensure that Ford Global packaging standards are 100 % followed by supplier and train them to follow standard
• Follow up with external customers(varies county)for export packaging approval (Engines, Head, block, crank, Short block & Long block)
• Ensuring ECM changes parts updated with new packing methods and same was approved by CFT
• Review weekly ISPR and TDL concerns to avoid packing and transport damages

Role in Internal packaging:

• Design new packing concept for internal movement parts
• Increasing line side efficiency by internal packaging concept development
• To identify / review action plan to reduce unsafe conditions /acts and maintain injury free man-day

Role in Material flow :

• Designing layout, PFEP and simulate material flow based on JPH and plan for required warehouse and equipment
• Developed material flow based on simulation study to achieve full JPH in machining and Engine Assembly plant
• Based on simulation data allocating location in HI-Bay to follow FIFO and Market place flow with standard levels of error proofing
• Developed material flow with help of PFEP and standardize smooth flow for line side delivery
• Design lean inventory level at line side and Warehouse
• Coordinate with Plant IT team to implement delivery system like SKS, SMART and OBL

Key Achievements:

• Successfully implemented packaging, warehouse location and line feeding setup in SMART & SKS system for 250 parts during Panther Engine (2.0 L) launch, major Program for Ford Sanand Engine Plan

Managed team of 4 company employees and 8 contract employees, overseeing training, and professional growth of employees

Role in Material Flow:

• Streamlined Material Flow for GREEN FIELD Operation from Dock to Warehouse to – Kitting /Sequencing to POF (For Raw Material) and End of line to Dock (For Finish Good)
• Supported Complete Material flow Projects from Greenfield site to launch of saleable Engine for New-Figo Aspire Vehicle and export markets
• Implementing layout, PFEP for new projects (DV5 and Dragon Engine) with team member support
• Implementing flow with help of PFEP and standardize smooth flow for line side delivery

Key Activities:

• Trained 25+ manpower for Receiving, Shipping, Export and Warehouse operation part of green field
• Successfully implemented packaging for 300+ parts; major Program for Ford Sanand Engine Plan (DV5, Dragon)

Role in External packaging:

• Resolve day to day operation packaging issue coordinating with supplier
• Validating packaging with approved form and share feedback for improvement
• ECC change packing validation and on time improvement
• Identifying opportunity for packing density improvement

Key Activities:

• Developed VBA program for ISPR and TDL tracker to ensure all issues are reported properly and solutions are getting tracked for future reference

Role in Internal packaging:

• Ensure 100% internal repacking material availability as per loop qty
• On time maintenance schedule and rework completion
• Zero contamination on internal containers which are used for line side delivery
• Ensuring 100% sign-off for internal repacking method for import parts

Key Activities:

• Developed internal packing material cleaning tracking system using excel VBA program to ensure 100% cleaning process

• Pursued learning opportunities to advance knowledge and take on leadership position.
• Ensure shortage parts delivery by coordinating with supplier and SCM
• Report out daily shortage part for day production
• Follow up with material gate to ensure on time truck invert
• Clearing Empty return to JIT suppliers to avoid line stop
• Attending daily rejection meetings to clear all quality issue parts
• Follow up with supplier and quality team for rejection parts clearance

Key Activities:

• Controlled incoming packaging deviation by 80% with continuous follow up by raising ISPR
• Contributed to team success by completing jobs quickly and accurately.