SATHISH KS

Dynamic and results-oriented leader with over 30 years of experience driving profitability and operational excellence in the manufacturing sector. Proven track record in business turnaround, revenue growth, and strategic planning across diverse markets, including Southeast Asia, India, and the UK. Expertise in business operations, product development, supply chain management, and key account management consistently leads to enhanced revenue and significant cost savings. Recognized for fostering high-performance teams and executing innovative strategies that transform organizations into profit centers while maintaining rigorous standards of operational effectiveness.

• Turnaround of injection molding division of EPL in 3 months’ time ramping up the volume from 450 M caps month to 740 M / month, thereby making it to a profitable plant.
• Turned around loss making EP UK plant in profitable in 8 months’ time by increasing the output of the plant from 6 million to 12 million tubes / month.
• Amcor Baroda Unit 1 which was producing 350 MT / Month to 700 MT / Month in a span of 6 months’ time, with Topline revenue increased from 6 Cr / Month to 13 Cr / Month, impacting the PBIT negative to positive.
• Implemented ELS( Enterprise Lean Six Sigma) while in Avery and the plant was ranked as one of the best for implementation and achieving a score of 4.2 /5. Was awarded global leadership award for the same.

• Safety / CSR Excellence:
• Secured highest score of 92/100 in APAC regions for global safety and compliance audit done by external agency while in Avery Dennison
• Achieved exceptional levels of 2.5M hours of injury-free plant and received ‘CEO Safety Award’ for Sonoco Indonesia plant for 3 consecutive years.
• Directed team to ensure compliance of all safety norms to achieve zero accidents through correct fire protection systems and safety equipment.
• Driven Safety Best Practices in terms of Static Management, LOTO, electrical safety, material handling etc. and established systems and process.
• Drove CSR activity where company had adopted a village for improvement of educational facilities while in Avery Dennison.
• Commercial Excellence:
• Significantly driven plant from 12 Cr Revenue per month to 100 Cr Revenue in Uflex Asepto by increasing the plant output and improving efficiency.
• Driven commercial excellence pocketed margin data base (PMDB) to improve the contribution margin product wise to improve profitability, at product level while in Amcor.
• Turnaround Unit1 Top-line revenue from 6 Cr / Month to 13 Cr / Month. By increasing the Output of plant 350 MT / Month to 700 MT / Month in a span of 6 months’ time, while in Amcor India.
• Acquired $5M growth for textile business in Indonesia and regained wallet share with key customers in Sonoco Indonesia.
• Administered weekly tracking system to control cost and proved pivotal in enabling the plants to achieve their EBIT targets on weekly basis while in Sonoco SEA.
• Commissioned new product line and executed business top line in a short span of 8 months, supported the sales team to drive the value plus initiatives to improve the CM in products which were below 20%.
• Increased overall profitability of plant to 2% by establishing MIT (Margin Improvement Team) to focus on underperformed CM products.
• Successfully driven V + (Value Plus projects) to create customer value as well as increase the profitability of the plant.
• Turned around the injection moulding division to a profitable plant within 3 months; boosted output to 740M caps PM from 450M caps; and enhanced plant operations to meet the Pharma standards of cleanroom.
• Driven the plant PBIT exceeding budget by 10K GBP for Q1 2007 by transforming a loss-making plant into a profitable plant in a duration of 8 months, while in EP UK, through implementation for continuous improvement and Six sigma methodology.
• Operational Excellence:
• Reduced Scrap from 10% to 4.5% in span of 5 months in Uflex Asepto
• Improved the output of the plant from 100 Million packs / month to 700 Million packs / Month in Uflex Asepto
• Consistently turned around output by implementing process and systems towards better periodic maintenance and CBM, bringing the machine conditions back to basics, while in Amcor
• Reduced 13% indirect manpower cost by optimizing manpower in Sonoco Indonesia in FY 2018 there by resulting in $ 56 K savings to company.
• Achieved $305K bottom line profit in financial year 2018 through execution of manufacturing excellence across 3 plants in South East Asia in Sonoco.
• Achieved 20% reduction in scrap through implementation of six sigma projects while in Amcor Indonesia.
• Realized savings of $185K by formulating strategies to reduce scrap through ELS in Avery Dennison
• Achieved cost saving of $249K through execution of Kaizens on packaging cost and MOE and improved productivity by 33% for coating machine, in Avery Dennison
• Reduce changeover time to 50% by leading team for various SMED projects.
• Achieved $100K worth energy saving in LPG and power saving across the plant.
• Increased productivity by 30% in printing and tubing sections, reduced change over time to 30 mins from 60 mins for printing and to 45 mins from 90 mins for tubing line.
• Attained highest score of 4.25.0 in APAC region for ELS while in Avery Dennison, the plant achieved this benchmarks in a span of 18 months.
• Strategic Projects:
• Devised initiation plans for SEA for next 3 years, identified critical capacity enhancement and attained Capex spending approval for the same.
• Rolled out oracle ERP system for Malaysia and Indonesia plants for business growth process.
• Increased plant capacity by 200 MT per month and developed a project team across all business functions to enhance the process, in Amcor Indonesia
• Governed complete strategy from concept stage to marketing, identified new product strategy and profitability by selecting the right machines while in Amcor Indonesia.
• Part of Greenfield project of TVS Mysore plant in installation and commissioning of Paint Shop Which consists of MS PT CED / Metal painting / Plastic Automatic painting / Al Chrome / De-rust Descaling / HR Painting / DM / ETP / STP Plants.
• Part of Brown field expansion of Avery Dennison ramped up the production with in a years’ time.
• Successfully integrated Bella Prima Operations into Amcor Way, as part of the M&A Team
• Quality Excellence:
• Implemented Quality system to reduce the customer complaints by implementing CTQ / CTP monitoring and improving process controls.
• Implemented Supplier and customer scorecards to measure and improve quality performance.
• Benchmarked GMP practices across the plant and attained FDA approval for the site to meet the Pharma standards.
• Streamlined NPD systems in plastic tube line, reviewed the existing systems and procedures, and designed internal controls and quality checks for various operational areas.
• Implemented cleanroom standards of class 10000 to uplift the plant to meet the Japanese quality standards.
• Supply Chain Excellence:
• As a part of the M&A team successfully integrated Bella Prima Operations into Amcor Way.
• Enhanced the OTIF to 98% from 23% and secured 50% SOW by handling key accounts of major customers.
• Improved the ware house space productivity by 33% by implementing Narrow aisle rack system and thereby saving 25 K pounds / month savings to company while in EP UK.
• Implemented lean systems like two bin, Kanban in ensuring to improve the OTIF to customer & reduction in the working capital/inventory
• New Product Development:
• Developed products in textile cores as per the customer needs.
• Interact with machinery/ film /adhesives and coating resin/ chemical suppliers and keep abreast of the latest trends in packaging / process technology.
• Bench mark towards improving the product quality and serviceability to world class performance.
• As Regional Textile head spear headed new product development with customers in SEA region as well customer trouble shooting of their process issues.
• Project Management:
• Rendered a complete revamp to the company’s productivity and quality standards while in Amcor India.
• Assisting in new projects and CAPEX process, in identifying capacity bottle necks, choosing right type equipment ensure that the machines are installed on time to support the business growth
• Through VSM implementation eliminated wastage, improved productivity by 45%, reduced lead time by 35%, reduced storage space requirement for finished goods, raw materials by 43%.
• As a core member of TQM – achieved the Deming award for excellence in 2003 while in TVS Motors.
• Mentored the team in establishing 3R inventory management system in entire plant while in TVS Motors and reduced the plant inventory from 31 days to 15 days.
• Human Capital development:
• Established training module for the new recruits.
• Motivated the multi-cultural staff and generated a team spirit with all working for a common goal.
• Enhanced employee performance through motivation and appraisal system based on Key Performance Indicators (KPI).
• Trained Front line Supervisors on Fundamental of leaderships and people managers on Leaderships, total 43 people managers were trained on the same.
• Ensure professional development and welfare of the staff, develop team spirit amongst them.

• Safety / CSR Excellence:
• Secured highest score of 92/100 in APAC regions for global safety and compliance audit done by external agency while in Avery Dennison
• Achieved exceptional levels of 2.5M hours of injury-free plant and received ‘CEO Safety Award’ for Sonoco Indonesia plant for 3 consecutive years.
• Directed team to ensure compliance of all safety norms to achieve zero accidents through correct fire protection systems and safety equipment.
• Driven Safety Best Practices in terms of Static Management, LOTO, electrical safety, material handling etc. and established systems and process.
• Drove CSR activity where company had adopted a village for improvement of educational facilities while in Avery Dennison.
• Commercial Excellence:
• Significantly driven plant from 12 Cr Revenue per month to 100 Cr Revenue in Uflex Asepto by increasing the plant output and improving efficiency.
• Driven commercial excellence pocketed margin data base (PMDB) to improve the contribution margin product wise to improve profitability, at product level while in Amcor.
• Turnaround Unit1 Top-line revenue from 6 Cr / Month to 13 Cr / Month. By increasing the Output of plant 350 MT / Month to 700 MT / Month in a span of 6 months’ time, while in Amcor India.
• Acquired $5M growth for textile business in Indonesia and regained wallet share with key customers in Sonoco Indonesia.
• Administered weekly tracking system to control cost and proved pivotal in enabling the plants to achieve their EBIT targets on weekly basis while in Sonoco SEA.
• Commissioned new product line and executed business top line in a short span of 8 months, supported the sales team to drive the value plus initiatives to improve the CM in products which were below 20%.
• Increased overall profitability of plant to 2% by establishing MIT (Margin Improvement Team) to focus on underperformed CM products.
• Successfully driven V + (Value Plus projects) to create customer value as well as increase the profitability of the plant.
• Turned around the injection moulding division to a profitable plant within 3 months; boosted output to 740M caps PM from 450M caps; and enhanced plant operations to meet the Pharma standards of cleanroom.
• Driven the plant PBIT exceeding budget by 10K GBP for Q1 2007 by transforming a loss-making plant into a profitable plant in a duration of 8 months, while in EP UK, through implementation for continuous improvement and Six sigma methodology.
• Operational Excellence:
• Reduced Scrap from 10% to 4.5% in span of 5 months in Uflex Asepto
• Improved the output of the plant from 100 Million packs / month to 700 Million packs / Month in Uflex Asepto
• Consistently turned around output by implementing process and systems towards better periodic maintenance and CBM, bringing the machine conditions back to basics, while in Amcor
• Reduced 13% indirect manpower cost by optimizing manpower in Sonoco Indonesia in FY 2018 there by resulting in $ 56 K savings to company.
• Achieved $305K bottom line profit in financial year 2018 through execution of manufacturing excellence across 3 plants in South East Asia in Sonoco.
• Achieved 20% reduction in scrap through implementation of six sigma projects while in Amcor Indonesia.
• Realized savings of $185K by formulating strategies to reduce scrap through ELS in Avery Dennison
• Achieved cost saving of $249K through execution of Kaizens on packaging cost and MOE and improved productivity by 33% for coating machine, in Avery Dennison
• Reduce changeover time to 50% by leading team for various SMED projects.
• Achieved $100K worth energy saving in LPG and power saving across the plant.
• Increased productivity by 30% in printing and tubing sections, reduced change over time to 30 mins from 60 mins for printing and to 45 mins from 90 mins for tubing line.
• Attained highest score of 4.25.0 in APAC region for ELS while in Avery Dennison, the plant achieved this benchmarks in a span of 18 months.
• Strategic Projects:
• Devised initiation plans for SEA for next 3 years, identified critical capacity enhancement and attained Capex spending approval for the same.
• Rolled out oracle ERP system for Malaysia and Indonesia plants for business growth process.
• Increased plant capacity by 200 MT per month and developed a project team across all business functions to enhance the process, in Amcor Indonesia
• Governed complete strategy from concept stage to marketing, identified new product strategy and profitability by selecting the right machines while in Amcor Indonesia.
• Part of Greenfield project of TVS Mysore plant in installation and commissioning of Paint Shop Which consists of MS PT CED / Metal painting / Plastic Automatic painting / Al Chrome / De-rust Descaling / HR Painting / DM / ETP / STP Plants.
• Part of Brown field expansion of Avery Dennison ramped up the production with in a years’ time.
• Successfully integrated Bella Prima Operations into Amcor Way, as part of the M&A Team
• Quality Excellence:
• Implemented Quality system to reduce the customer complaints by implementing CTQ / CTP monitoring and improving process controls.
• Implemented Supplier and customer scorecards to measure and improve quality performance.
• Benchmarked GMP practices across the plant and attained FDA approval for the site to meet the Pharma standards.
• Streamlined NPD systems in plastic tube line, reviewed the existing systems and procedures, and designed internal controls and quality checks for various operational areas.
• Implemented cleanroom standards of class 10000 to uplift the plant to meet the Japanese quality standards.
• Supply Chain Excellence:
• As a part of the M&A team successfully integrated Bella Prima Operations into Amcor Way.
• Enhanced the OTIF to 98% from 23% and secured 50% SOW by handling key accounts of major customers.
• Improved the ware house space productivity by 33% by implementing Narrow aisle rack system and thereby saving 25 K pounds / month savings to company while in EP UK.
• Implemented lean systems like two bin, Kanban in ensuring to improve the OTIF to customer & reduction in the working capital/inventory
• New Product Development:
• Developed products in textile cores as per the customer needs.
• Interact with machinery/ film /adhesives and coating resin/ chemical suppliers and keep abreast of the latest trends in packaging / process technology.
• Bench mark towards improving the product quality and serviceability to world class performance.
• As Regional Textile head spear headed new product development with customers in SEA region as well customer trouble shooting of their process issues.
• Project Management:
• Rendered a complete revamp to the company’s productivity and quality standards while in Amcor India.
• Assisting in new projects and CAPEX process, in identifying capacity bottle necks, choosing right type equipment ensure that the machines are installed on time to support the business growth
• Through VSM implementation eliminated wastage, improved productivity by 45%, reduced lead time by 35%, reduced storage space requirement for finished goods, raw materials by 43%.
• As a core member of TQM – achieved the Deming award for excellence in 2003 while in TVS Motors.
• Mentored the team in establishing 3R inventory management system in entire plant while in TVS Motors and reduced the plant inventory from 31 days to 15 days.
• Human Capital development:
• Established training module for the new recruits.
• Motivated the multi-cultural staff and generated a team spirit with all working for a common goal.
• Enhanced employee performance through motivation and appraisal system based on Key Performance Indicators (KPI).
• Trained Front line Supervisors on Fundamental of leaderships and people managers on Leaderships, total 43 people managers were trained on the same.
• Ensure professional development and welfare of the staff, develop team spirit amongst them.