Saravanan Kaliappan
Dindigul
Summary
Dynamic Industrial Engineering Manager with a proven track record at Sakthi Infra Tex Pvt Ltd, enhancing efficiency and spearheading innovation in knitwear production. Excelled in leadership and lean principles, achieving a 98% punctuality rate in deliveries. Skilled in workforce utilization and proficient with Seam SAM PACE software, consistently recognized for expertise in optimizing processes and fostering team growth.
Overview
18
18
years of professional experience
Work History
Industrial Engineering Manager
Sakthi Infra Tex pvt Ltd
Perundurai
06.2019 - Current
- Generated various types of knitwear products.
- Managed 1,800 machines.
- Designed detailed layouts including needle size, pressure foot, and suitable machine models with pictures.
- Calculated thread consumption using 'Seam Works' software, and ensured optimal thread utilization throughout the sewing process.
- Monitored and decreased changeover time.
- Minimized error rates by employing efficient quality practices with QAM.
- Enhanced efficiency through method improvements and automations, leading to cost savings.
- Enhanced overall team skills through structured training.
- Digitized our own barcode system for end-to-end order tracking.
- Optimized procurement processes by monitoring buyer-specific metrics.
- Performed yearly CPM assessments to determine CMT.
- Recognized by Decathlon buyer for expertise in SAM calculations through PACE.
Head - IE & Planning
Royal Classic Mills (Classic Polo)
Tirupur
06.2012 - 05.2019
- Focused on high-quality apparel including men’s shirts, trousers, and shorts.
- Managed workflow involving 460 machines.
- Presented strategies to enhance productivity each month.
- Prepared monthly profit and loss reports.
- Delivered comprehensive cost management during garment sampling stages.
- Provided incentives to employees surpassing 75% monthly efficiency.
- Strategized to boost factory capacity by leveraging historical performance data.
- Optimized planning stages to accelerate deliveries.
- Organized regular sessions to evaluate progress against goals.
- Boosted punctuality in deliveries, reaching a 98% success rate.
Industrial Engineer
Velocity Apparels
Ismailiya
11.2010 - 05.2012
- Specialized in creating high-quality denim and knitwear items.
- Managed 800 machines.
- Estimated sewing minutes for accurate cost calculations.
- Scheduled 21-day training programs, and fulfilled sewing floor requirements.
- Directed production processes for Denim and Knit goods with a focus on IE principles.
- Conducted self-factory evaluation training provided by the Target buyer.
Industrial Engineer
Slam clothing Pvt Ltd
Chennai
01.2009 - 10.2010
- Products- Men's & Women's top
- Managed the operation of 120 machines.
- Created operation bulletins incorporating balance measures.
- Optimized operator placement by leveraging skill data.
- Created an efficiency chart for tracking the learning curve effectively.
- Implemented strategies for decreasing downtime.
- Developed line balancing graphs to enhance hourly output.
Industrial Engineer
Lakshmi Graha Apparels
Coimbatore
04.2007 - 12.2008
- Optimized portfolio of formal and casual shirts, and trousers.
- Managed the operation of 100 machines.
- Finished the specialized AAMT course from KSA Technopack, USA.
- Streamlined workflow by collaborating on KANBAN Tray System implementation.
- Completed GSD implementation training through ITC.
Education
Diploma - Garment Technology
SSM Institute Of Textile Technology
Kumarapalayam03-2007
Skills
- Innovation
- Ergonomics assessment
- Leadership
- Quick learner
- Value stream mapping
- Workforce utilization
- Lean principles
- Proficient with [software]
Accomplishments
- Executed real-time video sessions, resulting in an 80% operator efficiency level
- Lowered the Machine-to-Man ratio from 1:1.45 to 1:0.98 by streamlining processes and reducing indirect labor
- Reduced indirect labor and increased sewing operators, resulting in a 25% decrease in Cost Per Minute (CPM)
- Implemented self-trimming techniques by operators, removing the need for end line trimming helpers, and minimized thread waste through efficient operation of UBT facilities
- Streamlined cutting and sewing processes by eliminating panel numbering and removing numbering stickers for designated styles
- Developed & executed a single-piece barcode system to track operator productivity and wages through machine scanning
Training program contribution
- Production Enhancement Training conducted by SriLankan Consultant at NIFT, Tirupur
- Lean Concepts & 6S Implementation Program, Waste Management Association (WMA), Sri Lankan Consultancy
- Advanced Analytical Method of Training (AAMT) for Sewing, Provided by USA Buyer
- GSD Training by ITC Management
- SAM Estimation Training, PACE (MTM 2 Tools software), Decathlon, France
Field Of Interest
- Administration
- Digitization
- Happiness survey
- People management
Language known
Tamil, English, Hindi, Arabic
Disclaimer
I declare that the information provided is accurate to the best of my knowledge and I take full responsibility for its correctness
Timeline
Industrial Engineering Manager
Sakthi Infra Tex pvt Ltd
06.2019 - Current
Head - IE & Planning
Royal Classic Mills (Classic Polo)
06.2012 - 05.2019
Industrial Engineer
Velocity Apparels
11.2010 - 05.2012
Industrial Engineer
Slam clothing Pvt Ltd
01.2009 - 10.2010
Industrial Engineer
Lakshmi Graha Apparels
04.2007 - 12.2008
Diploma - Garment Technology
SSM Institute Of Textile Technology
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