SANTO SAJI JOHN

TPS / Lean Manufacturing Engineer

• Developed and implemented lean manufacturing processes to reduce waste, improve efficiency and increase profitability.
• Analyzed production process flow to identify areas of improvement, bottleneck and develop solutions for increased productivity.
• Identification of non value added activities (NVA) and suggest suitable solution to eliminate the same.
• Identified customer needs, analyze and developed solutions based on user feedback including project scope and objectives.
• Improve cycle time / lead time from order receipt to dispatch.
• Established cost savings goals and tracked progress towards meeting those goals.
• Developed visual tools such as charts, graphs, maps. to track progress of lean projects throughout the organization.
• Trained team members on lean principles such as 5S, Kaizen, Kanban and Lean manufacturing principles.
• Conducted root cause analysis of production issues and identified corrective actions needed for resolution.
• Coordinated with vendors regarding supply chain strategies that support Lean Manufacturing objectives.
• Collaborated with cross-functional teams to ensure successful implementation of new processes or procedures related to Lean Manufacturing initiatives.
• Facilitated Kaizen events resulting in continuous improvements in safety, quality, delivery, cost reduction.
• Formulated action plans based on key findings from data analysis which led to increased efficiencies within the organization's operations.
• Devised, evaluated, implemented and oversaw multiple manufacturing projects of large scope from planning to completion.
• Provided economic modeling of business organization.
• Model the organization suitable for achieving Operational excellence.
• Documentation of all engineering activities according to established procedures.

Industrial engineering

• Developed, tested and implemented new production processes to reduce costs and improve efficiency.
• Analyzed existing production systems for potential process improvements and cost savings.
• Capacity analysis of the machinery, manpower and supporting departments such as stores, quality, testing etc.
• Enhancement of the production capacity to meet organizational goals.
• Devised, evaluated, implemented and oversaw multiple manufacturing projects of large scope from planning to completion.
• Designed efficient layouts of equipment, materials, and workspace to optimize workflow.
• Conducted research on the latest industrial engineering technologies, tools and techniques.
• Created detailed reports outlining current operations as well as proposed changes to improve productivity.
• Developed safety protocols to ensure compliance with OSHA standards in all facilities.
• Assessed current operational performance metrics and analyzed data trends to identify opportunities for improvement.
• Collaborated with management teams to design innovative solutions that reduced labor costs while increasing output quality.
• Provided guidance on the selection of appropriate machinery or equipment for specific applications.
• Evaluated existing materials handling methods and identified ways to reduce manual handling risks.
• Utilized computer-aided design software to create product designs or components and to modify layout for organized workflow.
• Worked closely with vendors on supply chain issues such as delivery schedules, pricing negotiations.
• Provided data-driven recommendations for operational planning support, capacity analysis and process improvement.
• Built relationships with interdisciplinary team to facilitate project objectives.
• Monitored plant performance against operating budgets and identify methods to cut expenses.
• Devised new equipment to meet worker and company requirements.
• Forecasted budgeting needs (CAPEX) and planned labor hours for new processes.
• Created and implemented cost-tracking, resulting in 20 lakhs annual savings.
• Directed engineering projects totaling 14.5 Cr's per year.
• Strategy development for operations based on management goals and vision.
• Documentation of all the required process for statutory, financial, quality and safety.
• Develop and implement operational excellence practices inside the industry.