Sanjeev Kumar
Summary
Operations & Continuous Improvement Project Senior Manager with 17.5 years of expertise in driving Industry 4.0 implementations for waste reduction, efficiency, and excellence through Lean, TPM, Six Sigma, and IoT. Expert in PQCDSM, dashboards, traceability, and business excellence tools like BSC, X-Matrix, and project management. Design tailored change management strategies to support digital transformation on the manufacturing shop floor. Driving Smart Factory Transformation | Lean & Digital Excellence | Business Operations Leader. Evaluate plant AI readiness covering sensors, automation systems, and PLCs, Traceability, Edge Devices, and Cloud Connectivity infrastructure.
Overview
17
17
years of professional experience
1
1
Certification
Work History
Sr. Manager - Project Management -IOT-Digitalization & Automation
ZYLOG Group
07.2024 - Current
- Company Overview: Leading thermoplastic elastomer compounder- Automotive, Medical & Healthcare, Wire & Cable, Building/Construction, Appliances and FMCG industries. (Zylog ElastoComp https://zylogelastocomp.com/)
- Driving Smart Factory Transformation | Lean & Digital Excellence | Business Operations Leader.
- Evaluate plant AI readiness covering sensors, automation systems, and PLCs, Traceability, Edge Devices, and Cloud Connectivity infrastructure.
- Leading thermoplastic elastomer compounder- Automotive, Medical & Healthcare, Wire & Cable, Building/Construction, Appliances and FMCG industries. (Zylog ElastoComp https://zylogelastocomp.com/)
Manager
Varroc Engineering Limited
12.2021 - 06.2024
- Digital transformation-IOT & Automation for the Operational Improvement project.
- Develop and align strategic activity plans across business units with the Group OpEx.
- Roadmap, support target setting and budgeting with BU and plant leadership.
- Lead IoT- and automation-driven digital transformation initiatives for real-time visibility, predictive analytics, and operational efficiency.
- Led MES-driven initiatives covering production planning, machine data, inventory, and quality control with real-time performance monitoring.
- Spearheaded manufacturing digitalization and business process automation projects. Identified and prioritized key data points, collaborating with digitization teams to enable data democratization through SAP-IoT integration.
- Support cost reduction and ROCE improvement by implementing, monitoring, and tracking high-impact projects beyond OEE, as defined by the Group OpEx Head.
- Identified the training needs and coordinate with the business HR as per requirement of new initiatives. & Competency development.
- Achieved 15% improvement in Overall Equipment Efficiency (OEE), reduced plant wise manufacturing cost by 10% through Cost saving projects under fixed cost and variable cost.
Project Manager & Operation-Lean-Leader
Alstom Manufacturing India Pvt. Ltd.
11.2019 - 12.2021
- Operation & Maintenance of Locomotive 12000 HP Indian Railways Engine, Audit and assessment workshops for departments.
- Achieved significant cost savings of 2 Cr. through Kaizen, 5S+Safety, Standard Work-WI, and (VSM) projects in Warranty & Fleet, LOCO-TAT. & MES-Digital Project at shop floor.
Manager
Rockman Industries Ltd. - Hero Group
08.2018 - 11.2019
- Operational Excellence-OpEx and QMS. (Overseeing casting processes for alloy wheels.)
- Achieved a remarkable 15% improvement in Overall Equipment Efficiency (OEE), reduced setup change time through Single-Minute Exchange of Die (SMED), and decreased rejection rates by 10%. Total Productive Maintenance (TPM) and developed Roadmap & KPI-Dashboard for performance tracking.
- Capacity improvement in CNC (Computer Numerical Control) and VMC (Vertical Machining Center) through Technology Upgrade, Machine & Process Optimization.
Deputy Manager-Operational Excellence / WCM
Hindalco Industries Ltd.
06.2015 - 07.2018
- Company Overview: Mumbai
- Excellence initiatives on WCM- Audit, Process Improvement, SPC & Six sigma Project with CFT.
- Improved QCDIPS and fuel efficiency in Remelt through Industry 4.0-enabled mill utilization project.
- Awarded by CII & NCQC for Lean Six Sigma-based quality and cost improvement.
- Drive waste elimination and KPI-focused efficiency through Kaizen, A3, and theme-based projects.
- Production planning, machine data, inventory, and quality control to real-time performance monitoring. For the (MES (Manufacturing Execution System).
- Mumbai
Assistant Manager-Operational Excellence
SKF India Ltd.
01.2014 - 06.2015
- Company Overview: Pune
- Specialized in Bearings, Seals, Services, and Lubrication management within the Automotive & Electrical Bearing Unit.
- 15 % improvement in Overall Equipment Efficiency (OEE). Reduced inventory levels through the implementation of KANBAN project. Cost savings through Kaizen Competition, (SMED), 5S, and Recognition & Reward (R&R) programs.
- Deployed TPM including Key Mgt. Indicator (KMI), Key Performance Indicator (KPI), and Key Activity Indicator (KAI).
- Pune
Assistant Manager-Operational Excellence & QMS
Piaggio Vehicles Pvt. Ltd.
03.2012 - 01.2014
- Company Overview: Baramati
- Automotive Engine production for light commercial vehicles.
- Implemented World Class Manufacturing (WCM), resulting in a significant 15% increase in productivity and a 10% reduction in quality defects.
- Ensured 100% audit compliance and conducted IATF 16949 Process Audits.
- Led Quality Improvement Projects (QIP) and facilitated Kaizen initiatives to drive continuous improvement in processes. Recognition & Reward (R&R) for employee engagement.
- Baramati
Senior Engineer-Production & Assembly
ADITYA BIRLA INSULATOR LTD.
02.2008 - 03.2012
- Company Overview: Gujarat
- Operations in the Machine Shop & Assembly division for India's largest manufacturer of high-performance insulators.
- 20 % increase in productivity by streamlining processes and improving workflow efficiency.
- Reduced quality defects by 12 % through the implementation of quality control measures and CI- initiatives.
- Quality, Cost, Delivery, Inventory, Productivity, and Safety, Morale (KPI-QCDIPSM) indicators, resulting in improved operational efficiency.
- Gujarat
Education
Post Graduate Diploma in Business Administration - Operation Management-WCM
Symbiosis University
Pune, Maharashtra06.2015
Bachelor of Technology - Mechanical Engineering
Biju Patnaik University of Technology
Rourkela, Odisha06.2008
10+2 - Science with Physics, Chemistry, and Mathematics
Bihar Intermediate Education Council
07.2001
10th Grade -
Bihar Secondary Education Council
05.1999
Skills
- Strategic Planning
- Operational Excellence
- Problem-Solving
- World-Class Manufacturing
- Lean Six Sigma Project
- Data Analyst-IoT-i40
- Project Management
- Digital Transformation / Automation
Certification
- T
- V S
- D Certified Lean Six Sigma Black Belt (CLSSBB), IN/14267/150070
- Lean Six Sigma Green Belt, CBEPL/FICCI/2020/0801
- World Class Manufacturing (WCM) - TPM Excellence, Assessors / Subject matter expert (SME) from SKF
Languages
English
Hindi
Gujarati
Marathi
Hobbies and Interests
- Net Surfing
- Watching Movies
- Listening Music
- Photography
- Travel
- Fitness
- Sports
Disclaimer
I Sanjeev Kumar hereby declare that the information here is true to the best of my knowledge and belief.
Personal Information
- Date of Birth: 02/07/83
- Gender: Male
- Nationality: Indian
- Marital Status: Married
- Religion: Hindu
Timeline
Sr. Manager - Project Management -IOT-Digitalization & Automation
ZYLOG Group
07.2024 - Current
Manager
Varroc Engineering Limited
12.2021 - 06.2024
Project Manager & Operation-Lean-Leader
Alstom Manufacturing India Pvt. Ltd.
11.2019 - 12.2021
Manager
Rockman Industries Ltd. - Hero Group
08.2018 - 11.2019
Deputy Manager-Operational Excellence / WCM
Hindalco Industries Ltd.
06.2015 - 07.2018
Assistant Manager-Operational Excellence
SKF India Ltd.
01.2014 - 06.2015
Assistant Manager-Operational Excellence & QMS
Piaggio Vehicles Pvt. Ltd.
03.2012 - 01.2014
Senior Engineer-Production & Assembly
ADITYA BIRLA INSULATOR LTD.
02.2008 - 03.2012
Bachelor of Technology - Mechanical Engineering
Biju Patnaik University of Technology
10+2 - Science with Physics, Chemistry, and Mathematics
Bihar Intermediate Education Council
10th Grade -
Bihar Secondary Education Council
Post Graduate Diploma in Business Administration - Operation Management-WCM
Symbiosis University
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