Summary
Overview
Work History
Education
Skills
Certification
Personal Information
Languages
Projects Handled
Significant Accomplishments
Languages
Timeline
Generic

SANTHOSH C

Hosur

Summary

Dynamic Factory Manager with a demonstrated history at PAGE INDUSTRIES LTD, specializing in production planning and operational excellence. Successfully implemented strategic process improvements that resulted in substantial cost savings while leading high-performing teams.

Proficient in manufacturing process management, driving collaboration, and fostering a culture of continuous improvement in fast-paced settings. Adaptable professional possessing proactive problem-solving skills, and excellent oral and written communication abilities. Offering many years of comprehensive experience in equipment operations, customer order fulfillment, and data entry. Comfortable lifting heavy loads and standing for an entire shift.

Overview

20
20
years of professional experience
1
1
Certification

Work History

Factory Manager (Production)

PAGE INDUSTRIES LTD
Bengaluru
06.2022 - 02.2025
  • Company Overview: Manufacturing & Operations – Innerwear and outerwear garment manufacturing of Jockey brands.
  • Taken care of the entire unit production activity, such as raw materials, production processes, packing section, and dispatch, consists of 800 manpower.
  • Planning and execution of line-wise style planning based on monthly requirement (MRP) allocation.
  • Plan and execution for weekly feeding alignment with PPC and RM stores.
  • Plan and execution for style changeover according to the monthly requirement.
  • Preparation of process sequence and process OB of complete types of products with virtual process planning.
  • Monitoring the unit cost and taking the corrective actions to control it within the specified limits.
  • Monitoring the new style's progress and completing the allocation quantity within the time.
  • Continuously driving the continuous improvement activities, like 5S, NVA reduction, Kaizens, etc.
  • Achieving market demand, monthly volume, through the operating plan.
  • Planning and execution of corrective actions for internal and external customer complaints.
  • Key Results Area (KRA) targets achievement monitoring and reviewing, as per organization policy.
  • Monitoring, reviewing, and guiding the supervisory team to achieve their KRA results.
  • Planning and execution of operator multiskilling development with skill matrix and stage matrix.
  • Planning of weekly maintenance activities for the Mechanical and Electrical departments.
  • Manufacturing & Operations – Innerwear and outerwear garment manufacturing of Jockey brands.

Deputy Manager

TVS MOTOR COMPANY
02.2018 - 06.2022
  • Planning for new product development in BMW projects (BMW G310 R/GS310R), APACHE RR310 engines, and vehicles.
  • Preparation of process sequence and process BOM of complete vehicle assembly with virtual process planning.
  • Preparation of assembly layout for multi-models in AGV conveyor for vehicles, and stop-and-go conveyor for engines.
  • Preparation of process sequence and process BOM of complete vehicle assembly with virtual process planning.
  • Conduct and prepare PFMEA to identify process controls with safety and quality.
  • The State of Build (SOB) and action plan are completed on the process flow diagram, and observed problems are routed to PQM (Product Quality Management).
  • Creation of PFD, control plan, and progressive PPAP for each build phase.
  • Monitoring EJO for Alpha, Beta, and QP trail concerns, and ensuring corrective actions are in progress.
  • Implementation of the Process Traceability System.
  • Synchronizing the new model with the existing model's job allocation.
  • Ensure all part-level follow-up and improve the same from QP build to SOP build.
  • Responsible for training and development for the new project process in vehicle assembly.
  • Identifying the sequence affecting the process and rearranging the sequence of fit in the trial stage itself.
  • New Equipment Handling and Operating Procedure Preparation and Updation.
  • Coordinating with the Purchase team for facilities procurement, such as jigs, fixtures, tools, direct materials, and consumables.
  • Coordinating with the SCM and secondary logistics team for part feeding management.
  • Maintain the vehicle BOM with respect to the latest design change, and conduct BOM audits periodically.
  • Maintained engine assembly quality parameters of processes and products as per BMW standards.
  • Planning and execution of corrective actions for internal and external customer complaints.
  • Reducing in-house rework by conducting 'Daily Quality' reviews and by practicing daily PDCA.
  • Controlling scrap costs by conducting station-wise monitoring.
  • Monthly MPCP targets achievement monitoring and reviewing, as per organization policy.
  • Preparation of Stage Matrix and Skill Matrix for Workmen.
  • Planning of weekly maintenance activities.
  • Facility management planning for a new project or product, and execution for mass production.
  • Achieving monthly production volume as per BMW requirements.
  • Maintain engine assembly quality parameters of processes and products as per BMW standards.
  • Planning and execution of workmen's training for new products, as per customer (BMW) standards.
  • Achieving 100% volume, as per the BMW volume requirement plan, month by month continuously, by overcoming production and quality-related issues.
  • Achieved productivity targets by reducing 5 manpower per shift through re-engineering projects.
  • Introduced an auto shell bearing selection station (Poka-yoke) to avoid model and size variation in shell bearing mix-ups.
  • Achieved cost savings of Rs. 12 lakhs per annum through Kaizen initiatives.

Senior Engineer

HYUNDAI MOTOR INDIA
12.2012 - 01.2018
  • Conveyor line setting as per plan, work man availability & work allotment to the associates and trainees as per skill matrix with comprising of 120 Men/shift
  • Coordinate with PPC & Stores to ensure the material availability as per plan in conveyor
  • Hourly monitoring the Quantity and Quality issues and taking the countermeasures immediately
  • Monitoring critical parameters like Engine numbering, Crankshaft and bearing selection, Piston matching, Head matching, Engine variants parts selection and Engine Testing
  • Preparing Incident report for any problem (For 4M) occurred more than 20 min for affecting line production
  • Taking corrective actions for Internal and External customer complaints
  • Trained and motivated all Associates and Trainees
  • Pass the engines as per Customer specification requirements
  • Taking care of PR (Process Rejection) and MR (Material Rejection) follow up and control
  • Achieved 100% output continuously by overcoming Production and Quality related issues
  • Awarded “Best Quality Improvement Award” in the year of 2015 by Executive Director (ED)
  • Introduced new program at Head loading Robot and avoided Major Cylinder Head process rejection
  • Member of Major line modification from Slot conveyor to Chain conveyor for wrong fitments and part missing complaints
  • Member of New vision system installed in Engine assembly for avoiding oil, water leakages and part missing related issues in field complaint
  • Awarded “Best supervisor Of the Month Award” on December’13 from our Executive Director (ED)

Senior Engineer

ASHOK LEYLAND LTD
10.2010 - 12.2012
  • Conveyor manning as per plan, work man availability & work allotment to the associates
  • Direct Testing & Direct pass improvement (Daily monitoring)
  • Raising Quality (OPL–One Point Lesson) alert in line to create customer complaint awareness to workmen
  • Co-ordination with Production Control / Material planning & Stores for FIFO&KANBAN approach

Engineer

TVS MOTOR COMPANY
07.2005 - 09.2010

Education

Executive Program - Operations and Supply chain Management

Indian Institute of Management
true
01.2024

DME - Mechanical Engineering

Thiagarajar Polytechnic college
Salem, Tamil Nadu
12.2005

Skills

  • Production Planning and Control
  • Supply Chain Management
  • Strategic Planning and Implementation
  • Manufacturing Process Management
  • Operations Excellence
  • Plant Operations and Administration
  • Cost control and optimization
  • Budgeting and Capex implementation
  • TPM / TQM
  • Project Management
  • New system implementation
  • Safety and Quality Operations
  • Statutory Compliance Management
  • Team Building and Leadership
  • Collaborator
  • Communicator
  • Planner
  • Change Agent

Certification

  • IMS Auditor from Six Sigma Consultancy
  • Internal Auditor from ABK-AOTS
  • 7 QC Tools and Techniques
  • TPM & TQM
  • Process Cost Management
  • Certified Trainer for Workers

Personal Information

Date of Birth: 03/14/85

Languages

  • Tamil
  • English
  • Kannada

Projects Handled

  • TVS – Victor, Star city, TVS King Engines
  • Ashok Leyland - Cargo vehicle engines, Defense vehicle engines, Generator Engines
  • Hyundai- i10 & i20 –Kappa Engines
  • BMW - G310R & GS310R – Engine & vehicle
  • TVS- Apache RR310– Engine & vehicle

Significant Accomplishments

  • Improved Productivity in sewing efficiency from 42% to 53% in span of 6 months’ time period.
  • Improved productivity of 20% in vest running lines through method improvements.
  • As a Key member to started and implement the 5S practices in the factory and achieved Basic 5S Platinum award from ABK-AOTS DOSOKAI, Chennai and moving towards Sustenance level.
  • Implemented 200+ kaizens and 600+ NVA reduction ideas from employees.
  • Achieved Total Cost Savings of Rs 18 Lakhs/annum through various process improvements and kaizen initiatives.
  • As a key member to support for inventory reduction cost saving of Rs.16 Lakhs/Annum in RM sub store.
  • Successfully completed the IMS external audit by Bureau Veritas (INDIA) and got awarded IMS certification.
  • Improved the Overall Process Effectiveness (OPE) from 39% to 51% by eliminating major losses in sewing and packing processes.
  • Taking the lead sustainability initiatives and implemented 2 energy saving projects with unit premises which given 6.4 Lakhs/saving per annum.
  • Achieved EBITDA margin 7 out of 10 styles through proper focus and implemented the method improvements.
  • Implemented QCO concept (Quick Change Over) for streamline the process in quick manner to achieve the line efficiency.
  • Implemented the SLT (Self Led Team) concept and successfully running 6 lines without supervision.
  • Implemented the Elite layout concept which have a greater number of changeovers for low volume styles for maintain the unit overall efficiency.

Languages

Tamil
First Language
English
Upper Intermediate (B2)
B2
Kannada
Intermediate (B1)
B1

Timeline

Factory Manager (Production)

PAGE INDUSTRIES LTD
06.2022 - 02.2025

Deputy Manager

TVS MOTOR COMPANY
02.2018 - 06.2022

Senior Engineer

HYUNDAI MOTOR INDIA
12.2012 - 01.2018

Senior Engineer

ASHOK LEYLAND LTD
10.2010 - 12.2012

Engineer

TVS MOTOR COMPANY
07.2005 - 09.2010

Executive Program - Operations and Supply chain Management

Indian Institute of Management

DME - Mechanical Engineering

Thiagarajar Polytechnic college

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