Summary
Overview
Work History
Education
Skills
Websites
Certification
Extracurricular Activities
Personal Information
Languages
Timeline
Hi, I’m

Sudhir Samal

Thane
Sudhir Samal

Summary

Seasoned Head of Operations at Raychem RPG, adept in lean manufacturing and Six Sigma methodologies, I excel in driving operational excellence and efficiency improvements by achieving 1lakh nos. meters per month in GAS meter production line. With a proven history at CEAT LTD., including a 15% increase in tyre curing efficiency, my leadership and problem-solving skills have consistently enhanced plant productivity and profitability.

Overview

20
years of professional experience
1
Certification

Work History

Raychem RPG
Thane

HEAD OF OPERATIONS
09.2023 - Current

Job overview

  • My current role is to oversee the overall plant operation for two business units of Raychem, where one unit engages in gas meter manufacturing and the other in the engineering business unit.
  • I am responsible for: Open order execution, Plant production efficiency, Warehouse management for both RM and FG, Customer complaints, Capex and Opex budgeting, Monitoring P&L of plant, Managing audits, Overall process improvements by doing Value stream mapping, Implement lean manufacturing practices, Implement industries best practices wrt machine and method.
  • Successfully met the highest-ever production target for FY24.; by developing people and improving system and process; Awarded as the best people manager for FY24.
  • Reduce the customer complaint percentage from 35% to 5% in FY24 in EBU business.

CEAT LTD.
Mumbai

SR. MANAGER VENDOR DEVELOPEMENT
04.2021 - 09.2023

Job overview

  • My current role is to reduce risk to my organization by improving vendor capability, in terms of process, machine and people.
  • I am responsible for: Conversion cost calculation, Improvement in Annual plan goal compliance, Reduce scraps and defects by following DMAIC methodology, Overall process improvements by doing Value stream mapping, Implement lean manufacturing practices, Implement industries best practices wrt machine and method.
  • Resolve chronic green tube length variation issues by low-cost automation in the extruder, and improve efficiency by 7%, saving eight man-hours per day.
  • 15% Increase in Tyre curing efficiency by doing process mapping and reducing handling losses.
  • Digitalize the CEAT logo printing on tubes at all tube units and save workforce costs by eliminating the manual printing process.
  • Successfully completed VSM project in tube packing area by doing automation in accessories assembly and eliminating all manual processes, saved sixteen workforces.
  • Trainer Quality Circle handling more than fifty teams. Increase the percentage of people involved in improvement activities from 10% to 40% in all OS locations.
  • Leading major cost saving projects to improve plant breakeven.

CEAT LTD.
Hyderabad

SR. MANAGER PRODUCTION
04.2017 - 04.2021

Job overview

  • Oversee all daily operations of the plant, from production and manufacturing to ensuring that policies and procedures are followed, and develop processes that will maximize stewardship, safety, quality, and productivity.
  • I am responsible for: Plan, organize, direct, and run optimum day-to-day operations to exceed our customers' expectations, Increase production, assets capacity and flexibility while minimizing unnecessary costs and maintaining current quality standards, Be responsible for production output, product quality, and on-time shipping, Allocate resources effectively and fully utilize assets to produce optimal results, Implement strategies in alignment with strategic initiatives and provide a clear sense of direction and focus, Monitor operations and trigger corrective actions, Share a trusting relationship with outsourcing partner, Collect and analyze data to find places of waste or overtime, Commit to plant safety procedures, Develop systems and processes that track and optimize productivity and standards, metrics, and performance targets to ensure effective return on assets, Address outsourcing partner issues or grievances, Stay up to date with the latest production management best practices and concepts.
  • Set up process for tyre and tube in house kitting.
  • Resolve chronic customer complaint by doing automation in balancing mark on tyre in balancing machine.

CEAT LTD.
Bhandup

PRODUCTION MANAGER
10.2012 - 04.2017

Job overview

  • My role is to ensure manufacturing processes run reliably and efficiently in my department in all shifts.
  • I am responsible for: Planning and organizing production schedules, Assessing project and resource requirements, Ensuring that health and safety regulations are met in my department, Determining quality control standards for my department, Overseeing production processes, Do PDCA for abnormalities and scrap, Organizing the repair and routine maintenance of production equipment, Supervising and managing the work of junior staff, Organizing relevant training sessions, Prepare Work Instruction and SOP for plant operation.
  • Implement KANBAN in 4 roll calender area.
  • QIP on Cp Cpk improvement and eliminating bandwidth variation problem.
  • SMED in band building machine and improve the flexibility of SKUs.
  • SMED in 3 roll calender for 2W ply cushioning and mitigate the risk of having a dependency on only one calender machine.

TVS TYRES
Rudrapur

ASST. MANAGER PREPARATION AREA
12.2011 - 10.2012

Job overview

  • My role was to ensure smooth operation of the department and adhering company norms and standards.
  • I am responsible for: Planning and organizing production schedules, Assessing project and resource requirements, Ensuring that health and safety regulations are met, Determining quality control standards, Overseeing production processes, Re-negotiating timescales or schedules as necessary, Selecting, ordering, and purchasing materials, Organizing the repair and routine maintenance of production equipment, Consulting with production planning team, Supervising and managing the work of junior staff, Organizing relevant training sessions.
  • Restructure department operation and Reduce workforce in extruder, 4roll calendar & bead winding to improve Kh per Man Hr.
  • Reduce fabric scrap in calendar (12% to 2%) by eliminating the root causes.
  • Reduce work away tread generation (22% to 5%) by working chronic failure modes in extruder machine.
  • Robust systems in plants by implementing KANBAN system.

GOOD YEAR INDIA LTD.
Ballabgarh

AREA MANAGER
10.2008 - 06.2011

Job overview

  • My role was to monitor and deliver production in the band building department in shift.
  • Resolve chronic air trap issue in band building.

APOLLO TYRES
Vadodara

TRAINING OPERATING ENGINEER
02.2005 - 10.2008

Job overview

  • To fulfill all PQCDSM parameters in my shift.
  • Handling tyre building department.
  • Improve the tyre building production by 2%, by giving suggestions on eliminating losses during production.

Education

NIIBMT
Delhi

Bachelor of Technology
01.2009

S.C.T.E.V.T, Odisha
Odisha

Diploma from Electrical engineering
01.2004

ISPAT VIDYAMANDIR, SEC- 19
Rourkela

12th
01.2001

BSE Odisha
Rourkela

10th
01.1999

Skills

  • Six Sigma green belt
  • Six Sigma black belt
  • QIP
  • DEMING Audit preparation
  • Conversion cost
  • 5S and Kaizen
  • Scrap reduction
  • Plant operation
  • Production efficiency
  • Capex budgeting
  • Opex budgeting
  • P&L management
  • Value stream mapping
  • Lean manufacturing
  • Process improvement
  • Vendor management
  • Customer service
  • Team building
  • Employee training
  • Project management
  • Data analysis
  • Audit management
  • Organizational development
  • Workforce planning
  • Cross-functional coordination
  • Business analysis
  • Logistics management
  • Safety management
  • Operational excellence
  • Decision-making
  • Multitasking
  • Records organization and management
  • Policy/program development
  • Written communication
  • Customer relations
  • Adaptability and flexibility
  • Oversee administrative functions
  • Delegation
  • Effective communication
  • Supervision and training
  • Business process reengineering
  • Profit and loss accountability
  • Business management
  • Purchasing and planning
  • Performance improvement
  • Employee relations
  • KPI tracking
  • Revenue generation
  • Cost analysis and savings
  • Continuous improvement
  • Communication
  • Resource allocation

Certification

Lean six sigma courses, simplilearn

Extracurricular Activities

Participated in various quality improvement projects., 04/01/23

Personal Information

  • Date of Birth: 04/26/84
  • Nationality: Indian
  • Marital Status: Married

Languages

English
Advanced
C1
Hindi
Proficient
C2
Kanad
Beginner
A1

Timeline

HEAD OF OPERATIONS

Raychem RPG
09.2023 - Current

SR. MANAGER VENDOR DEVELOPEMENT

CEAT LTD.
04.2021 - 09.2023

SR. MANAGER PRODUCTION

CEAT LTD.
04.2017 - 04.2021

PRODUCTION MANAGER

CEAT LTD.
10.2012 - 04.2017

ASST. MANAGER PREPARATION AREA

TVS TYRES
12.2011 - 10.2012

AREA MANAGER

GOOD YEAR INDIA LTD.
10.2008 - 06.2011

TRAINING OPERATING ENGINEER

APOLLO TYRES
02.2005 - 10.2008

NIIBMT

Bachelor of Technology

S.C.T.E.V.T, Odisha

Diploma from Electrical engineering

ISPAT VIDYAMANDIR, SEC- 19

12th

BSE Odisha

10th

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Sudhir Samal