SATYABRATA SAHOO
Operations Head with P&L - Automotive Manufacturing Industries
Pune,MH
Summary
Enterprising leader & planner with a string record of contributions in streamlining operation & enhancing Bottom line & turnaround EBITDA, heightening productivity, system & procedures
Operations professional with strong background in streamlining processes and enhancing productivity. Skilled in leading cross-functional teams and executing strategic plans to achieve organizational goals. Known for flexibility and reliability in dynamic environments, with excellent problem-solving abilities and focus on delivering results.
Overview
24
24
years of professional experience
9
9
Languages
Work History
Operations Head Product Business
Kalyani Techno Forge Ltd
03.2024 - Current
- Reporting to Vice President Operations business Unit Head monitoring overall plant from raw material supply to finish good dispatch to customers, production planning & control - shop floor planning, procurement, and control & troubleshooting for achieving planned periodic schedules through 100% capacity utilization of plant by working with central planning.
- Responsible for Production, Plant P& L maintaining the EBITDA- 27% as per the Management Target.
- Maintaining proper working conditions, housekeeping, statutory compliance, and safety at the workplace to steer delivery capacity.
- Analyzing material requirement and shop requirement plans and suggesting course correction, facilitating vendor development, optimizing vendor payment cycle and ensuring inventory stock / audits as per system.
- Working towards meeting division targets for cost booking and reviewing liquidation plan.
- Formulating and implementing SOP's and meeting internal operational KPI / QMS.
- Liaising with maintenance team for developing & implementing preventive maintenance schedules for improving overall reliability and safety of plant, personnel, and production processes.
- Leading NPD team to deliver the Proto & New part development within 12 -48 Week & SOP.
- RFQ Floating to Machine manufacturer, Commercial finalization, DAP, FAT & SAT with successful installation & commission of New Manufacturing, Assembly line to meet the strategic business.
- Major contributor for NPD & Execution ,SOP of BORG -WARNER,SCHAEFFLER,STELLANTIS Compass SUV Drive shaft & POLO AT.
Head of Operations
Kalyani Technoforge Ltd
03.2024 - 05.2025
- Increased customer satisfaction by actively addressing concerns and ensuring timely resolutions.
- Collaborated with executive leadership on strategic planning initiatives to drive business growth.
- Developed comprehensive training programs for staff, enhancing team performance and skill sets.
- Implemented risk assessment procedures to minimize potential disruptions across all areas of operation.
- Improved overall productivity with the introduction of innovative process improvement initiatives.
- Led cross-functional teams to achieve company goals, fostering collaboration and communication.
- Streamlined operational processes by identifying inefficiencies and implementing best practices.
- Oversaw supply chain management, ensuring timely delivery of products and services to customers.
- Managed crisis situations effectively by developing response plans in advance.
- Managed vendor relationships, negotiating contracts for maximum value and efficiency.
- Ensured compliance with industry regulations and company policies, mitigating potential risks.
- Built a high-performance culture by recruiting top talent and promoting professional development opportunities for staff members.
- Implemented data-driven decision-making processes, leveraging analytics to optimize operations.
- Automated manual processes using technology solutions, increasing accuracy and efficiency within operations.
- Spearheaded continuous improvement projects, resulting in enhanced business performance.
- Optimized inventory levels by implementing demand forecasting tools and techniques.
- Developed and maintained robust business continuity plans, ensuring operational resilience in face of unforeseen challenges.
- Strengthened compliance with industry regulations by updating policies and conducting regular staff training sessions.
- Directed launch of new product lines, coordinating cross-functional teams to achieve market penetration and sales targets.
- Drove technology integration strategies, modernizing legacy systems and facilitating seamless data flow.
- Enhanced operational transparency with implementation of advanced reporting systems, providing real-time insights to stakeholders.
- Negotiated with technology vendors to secure advantageous terms, integrating cutting-edge solutions that drove operational efficiency.
- Improved inventory accuracy and warehouse organization through adoption of advanced tracking systems and storage solutions.
- Fostered culture of continuous improvement, encouraging innovation and employee engagement through targeted training programs.
- Reduced environmental impact by implementing sustainable practices and eco-friendly operations, gaining recognition in industry.
- Spearheaded operational improvements, leading to streamlined processes and enhanced efficiency across departments.
- Streamlined logistics and distribution networks, ensuring timely delivery of products and reducing transportation costs.
- Coordinated with marketing and sales departments to align operational capabilities with strategic growth initiatives.
- Achieved significant cost reductions by renegotiating supplier contracts and optimizing inventory management practices.
- Enhanced team productivity with implementation of agile methodologies, significantly reducing project turnaround times.
- Empowered team leaders with autonomy in decision-making, fostering dynamic and responsive operational environment.
- Optimized customer service protocols, elevating customer satisfaction and loyalty through personalized service initiatives.
- Assisted in recruiting, hiring and training of team members.
- Negotiated price and service with customers and vendors to decrease expenses and increase profit.
- Reported issues to higher management with great detail.
- Trained and guided team members to maintain high productivity and performance metrics.
- Interacted well with customers to build connections and nurture relationships.
- Implemented innovative programs to increase employee loyalty and reduce turnover.
- Monitored daily cash discrepancies, inventory shrinkage and drive-off.
DGM Operations
Autoliv India LTD
04.2023 - 03.2024
- Reporting to Vice President Operations business Unit Head monitoring overall plant from raw material supply to finish good dispatch to customers, production planning & control - shop floor planning, procurement, and control & troubleshooting for achieving planned periodic schedules through 100% capacity utilization of plant by working with central planning.
- Responsible for Production, Plant P& L maintaining the EBITDA as per the Management Target.
- Maintaining proper working conditions, housekeeping, statutory compliance, and safety at the workplace to steer delivery capacity.
- Analyzing material requirement and shop requirement plans and suggesting course correction, facilitating vendor development, optimizing vendor payment cycle and ensuring inventory stock / audits as per system.
- Working towards meeting division targets for cost booking and reviewing liquidation plan.
DGM Operations
ENURANCE TECHNOLOGY LTD
08.2019 - 04.2022
- Reporting to Vice President corporate strategy & Business Unit Head monitoring overall plant from raw material supply to finish good dispatch to customers, production planning & control - shop floor planning, procurement, and control & troubleshooting for achieving planned periodic schedules through 100% capacity utilization of plant by working with central planning.
- Responsible for Production, Plant P& L keeping the EBITDA as per the Management Target.
- Maintaining proper working conditions, housekeeping, statutory compliance, and safety at the workplace to steer delivery ability.
- Analyzing material requirement and shop requirement plans and suggesting course correction, easing vendor development, perfecting vendor payment cycle, and ensuring inventory stock / audits as per system.
- Working towards meeting division targets for cost booking and reviewing liquidation plan.
- Formulating and implementing SOP's and meeting internal operational KPI / QMS.
- Consulting with maintenance team for developing & implementing preventive maintenance schedules for improving overall reliability and safety of plant, personnel, and production processes.
- Formulating P.Q.C.D.S.M data for machine shop, yearly expense budget, and planning monthly Expense vs Budget.
- Heading TPM activities - JH & KK pillar, implementing CAPEX plans.
- Coordinating with quality department for detection potential deficiencies and implementing corrective actions through Why Why Analysis, IATF 16949: 2016, 7QC Tools, Quality Systems and Process Control Records.
- Collaborating with HR department for hiring, resolving grievances, signing agreements and maintaining amicable employee relations; conducting Skill Development training and ensuring OJT to employees.
Value Stream Manager - Head Operations
GKN Driveline India Ltd.
07.2017 - 07.2019
- Reporting to Plant Director - (Business Unit Head for West), monitoring overall plant from raw material supply to finish good dispatch to customers, production planning & control - shop floor planning, procurement, and control & troubleshooting for achieving planned periodic schedules through 100% capacity utilization of plant by working with central planning.
- Maintaining proper working conditions, housekeeping, statutory compliance, and safety at the workplace to steer delivery capacity.
- Analyzing material requirement and shop requirement plans and suggesting course correction, easing vendor development, optimizing vendor payment cycle and ensuring inventory stock / audits as per system.
- Working towards meeting division targets for cost booking and reviewing liquidation plan.
- Formulating and implementing SOP's and meeting internal operational KPI / QMS.
- Liaising with maintenance team for developing & implementing preventive maintenance schedules for improving overall reliability and safety of plant, personnel, and production processes.
- Major contributor for Development & Execution of Zeep Compass SUV Drive shaft & POLO AT with NPD and R&D team.
- Enhanced the BAL line drive shaft productivity from 8k sets to 14.5k sets per month.
- Major contribution in new drive line set up from Scratch in KADI, Gujarat Plant including Process development & Machine selection for SMC (Suzuki Motor Corporation).
- Key Person to drive DES (Driveline Excellence System) in Asia Pacific Drive Line Plants.
- Improved the drive shaft sales from $1.73Mn to $3.95Mn Per month by developing & executing the drive shaft for Ford, Fiat, SMC in Pune & Gujarat Plant.
- Improved the OEE from 60% to 85-90% across the Plant (Pune & Gujarat) through proper Process improvement, Enhancing the Operator Skill by introducing training through DOJO cell.
- SPOC for implementing DES (drive line Excellence System) in all Driveline Plant of Asia Pacific.
Executive Manager - Shop Floor Operation
Cummins India Ltd.
04.2015 - 04.2017
- Worked as the Section in Charge for V28 Cylinder Block, Gear Case Cover with manpower of 30+ including Senior Manager, Manager, Asst., Manager, Junior Shop Manager & Associates.
- Leading unionized blue color team of 1200 nos.
- Participated in 2-agreements with a collaborative teamwork -resulted 20% Production capacity enhancement.
Plant Manager - Operation
SMC Pneumatics (I) Pvt. Ltd.
03.2012 - 02.2015
- Worked as KPO (Kaizen Promotion Officer) in Chennai plant.
- Spearheaded all legal issues - property tax, factory license, & other statutory requirement of Tamil Nādu, led SOI booking to reach at customer's end within same day for local customer & within 3 days to other state customers.
- Attained 80% dispatch target of sales order booked and plant sales growth from 80 lacs/ month - 7.6 Cr / month with the same infrastructure & 12% increase in direct Manpower.
Dy. Manager Production
Rico Auto Industries Ltd.
03.2011 - 02.2012
- Functioned as KPO (Kaizen Promotion Officer) in Rail, Sanand Plant.
- Responsible for Cylinder Block Machine shop.
Senior Engineer / Executive (Machine-shop In-charge)
HTTS (I) Pvt. Ltd. & Endurance Technology Ltd.
01.2008 - 03.2011
Asst. Manager (Machine-shop In-Charge)
Plasma Technology Pvt. Ltd.
02.2006 - 01.2008
Production Officer
I.S.A. P Pvt. Ltd.
01.2004 - 02.2006
CNC Operator
Achhuk Consultants & Engineers Pvt. Ltd.
05.2001 - 12.2003
Education
GMBA - Corporate Finance
Liver Pool John Moore's
PGPM - Strategy & Leadership
IMT
MBS - E MBA Operations
IBMR
Post-Graduate Certificate - Production & Materials
IBMR
Pune 05.2001 -
B.Tech. - Mechanical Engineering
IME
Diploma - Mechanical Engineering
Board of Technical Education Karnataka
AMP College Of Engineering 05-2001
Skills
Production Planning
Areas Of Expertise
Machining of Ferrous, Non-ferrous, Casting & Forged component, Conventional SPM, CNC, VMC, HMC of Fagor, Fanuc, Mazak, Siemens Controller, Leak Testing Air/Water, Honing, Impregnation, Broaching, Hard milling, Grinding, Gear Grinding, Hobbing, Shaving, Clutches, Pneumatic Cylinders, Various Pneumatic Valves, Air Dryer, Various Automotive, Marine, Locomotive, Power Generation Engines, Engine Assembly, Cutting Robot Assembly, Drive Shaft Assembly, Gear Box Assembly, Borg-Warner, Stelantise, Schaeffler, Tata Motors, Bajaj Ltd., Hero Motors, Ledford German & India, JCB India Ltd., TVS Motors, WABCO India Ltd., Force Motors Ltd., GE, Ashok Leyland, Asia Motors, Volks Wagon, Bharat Forge Ltd., Novatics India Ltd., Maruti Udyog Ltd., Bosch Ltd., Brakes India, Minda, Other Pharmaceutical, Agriculture & Machine Manufacturer
Personal Information
- Passport Number: Z7103686
- Date of Birth: 08/04/80
Accomplishments
- Documented and resolved - The issue of high COPQ & reduced by 80% which led to improve SW EBITDA from negative 4.0 to Positive 13.2% - Autoliv
- Devised continuous process improvements to minimize waste and reduce costs; implemented projects which resulted in annual savings of 37.9 million USD (379 Lacs INR)
- Doubling the Sales from 13cr INR/Month to 27Cr INR /Month through asset sweating resource utilization method & double the productivity
- Collaborated with team of 22 in the development of Borg Warner diff case development & Produced the Proto within 10 Week time against the target of 40 Week
- Achieved sales Proto to 15Cr INR/Month by completing green field project from scratch with accuracy and efficiency within 9 months time
Studying & Understanding Devine Power
Enterprising leader & planner with a string record of contributions in streamlining operation & enhancing Bottom line & turnaround EBITDA, heightening productivity, system & procedures Sector: Automobile/ automotive/ All OEMs/ Pneumatics & automation
Six Sigma Green Belt certified with 23 years of expertise in Production Management, Plant Operations, Quality Assurance & Green field Projects with skills to enhance production capacity, resource optimization, cost control through usage of tools / methodologies like TPM, SIGMA(6σ), 5S, Kaizen, Poka-Yoke, VSM, SPC, PFMEA, PPAP, 7QC Tools, ACMA, SMED, MOST, Lean Manufacturing System, WCM, IATF:16949, OSHAS-18001, ISO 5001 & PMS
Timeline
Head of Operations
Kalyani Technoforge Ltd
03.2024 - 05.2025
Operations Head Product Business
Kalyani Techno Forge Ltd
03.2024 - Current
DGM Operations
Autoliv India LTD
04.2023 - 03.2024
DGM Operations
ENURANCE TECHNOLOGY LTD
08.2019 - 04.2022
Value Stream Manager - Head Operations
GKN Driveline India Ltd.
07.2017 - 07.2019
Executive Manager - Shop Floor Operation
Cummins India Ltd.
04.2015 - 04.2017
Plant Manager - Operation
SMC Pneumatics (I) Pvt. Ltd.
03.2012 - 02.2015
Dy. Manager Production
Rico Auto Industries Ltd.
03.2011 - 02.2012
Senior Engineer / Executive (Machine-shop In-charge)
HTTS (I) Pvt. Ltd. & Endurance Technology Ltd.
01.2008 - 03.2011
Asst. Manager (Machine-shop In-Charge)
Plasma Technology Pvt. Ltd.
02.2006 - 01.2008
Production Officer
I.S.A. P Pvt. Ltd.
01.2004 - 02.2006
Post-Graduate Certificate - Production & Materials
IBMR
05.2001 -
CNC Operator
Achhuk Consultants & Engineers Pvt. Ltd.
05.2001 - 12.2003
PGPM - Strategy & Leadership
IMT
MBS - E MBA Operations
IBMR
B.Tech. - Mechanical Engineering
IME
GMBA - Corporate Finance
Liver Pool John Moore's
Diploma - Mechanical Engineering
Board of Technical Education Karnataka
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