Sudhir Samal

Oversaw operations for two business units, ensuring seamless processes in gas meter manufacturing and energy sectors.

Executed open orders, guaranteeing timely product delivery to customers.

Enhanced production efficiency through continuous process improvement initiatives.

Managed warehouse operations for raw materials and finished goods, optimizing inventory flow.

Addressed customer complaints to elevate overall service quality and satisfaction.

Developed Capex and Opex budgets aligned with organizational financial objectives.

Monitored plant P&L, maintaining profitability and operational effectiveness across departments.

Implemented lean manufacturing practices to optimize workflows and reduce waste.

Reduced organizational risk by enhancing vendor capabilities in processes, machinery, and personnel.

Calculated conversion costs to support financial planning and decision-making.

Improved compliance with annual planning goals through strategic oversight.

Minimized scrap and defects using DMAIC methodology for operational excellence.

Executed value stream mapping to identify and implement overall process improvements.

Adopted lean manufacturing practices to enhance efficiency and reduce waste.

Implemented industry best practices related to machinery and methods for optimal performance.

Resolved chronic green tube length variation through low-cost automation, improving efficiency by 7% and saving 8 man-hours daily.

Oversaw daily operations, enhancing policy compliance and safety protocols.

• Directed cross-functional teams to execute strategic initiatives, improving operational effectiveness.
• Developed operational plans that increased productivity and optimized supply chain processes.
• Analyzed business performance data, delivering forecasts for upper management insights.
• Produced reports on project activities and performance metrics for stakeholder review.
• Managed production output, ensuring product quality and timely shipping.

Executed shift changes and operational functions to uphold standards.

Mediated employee conflicts, facilitating effective resolutions.

• Restructured department operations to enhance efficiency and reduce manpower in extruder, four-roll calendar, and bead winding.
• Reduced fabric scrap in calendar from 12% to 2% by addressing root causes.
• Minimized work away tread generation from 22% to 5% by resolving chronic failure modes in extruder machine.
• Implemented KANBAN system to establish robust operational processes.
• Planned and organized production schedules to optimize resource utilization.
• Ensured compliance with health and safety regulations throughout production processes.
• Supervised junior staff, providing guidance and organizing relevant training sessions.
• Liaised with production planning team to align project requirements and schedules.

• My role was to monitor and deliver production in band building department in shift
• Achievements:-
• Resolve chronic air trap issue in band building

• Oversaw production operations for light commercial vehicle tyre building in first and second stages.
• Achieved zero breakdown incidents during shifts.
• Ensured safety protocols for personnel and machinery during all shifts.
• Managed inventory supplies for seamless transition to next shift.
• Maintained zero rejection and rework rates throughout shifts.

• Fulfilled all PQCDSM parameters during each shift.
• Managed operations within tyre building department to ensure quality standards.
• Monitored production processes to maintain compliance with established metrics.