Venkatesh Balasubramaniyan
Summary
Industrial Engineer | 8+ Years in Manufacturing & Plant Operations | Lean Expert
Results-driven Industrial Engineer with over 8 years of experience optimizing manufacturing and plant operations. Proven track record of enhancing production efficiency, reducing waste, and implementing Lean methodologies to drive operational excellence. Recognized for leading impactful process improvement initiatives that yield measurable gains in efficiency, quality, and cost savings. Adept at managing cross-functional teams, streamlining workflows, and fostering a culture of continuous improvement. Seeking to apply both technical acumen and leadership skills in a Factory Manager role to elevate performance and operational outcomes.
Overview
12
12
years of professional experience
Work History
Assistant Manager
Arvind Limited
06.2023 - Current
- Supervised daily operations to meet performance, quality, and service benchmarks.
- Fostered a positive work environment by building strong working relationships with staff.
- Reduced Production Cycle Time by 20% through Process Mapping and Kaizen Events .
- Coordinated Sample Approvals and Pilot Runs , ensuring all pre-production requirements were met.
- Reviewed Engineering Drawings and BOMs , reducing rework and improving manufacturing accuracy.
- Partnered with R&D, QA, and Technical teams to finalize production documentation.
- Led Pre-Production Meetings to align stakeholders on production readiness and timelines.
- Led a project implementing SMED techniques , reducing average changeover time on 2 lines.
- Collaborated with Maintenance and Production teams to eliminate non-value-added setup activities.
- Created Changeover Checklists and Visual Work Instructions to streamline setups.
- Mapped Line Design and current processes using Time Studies to identify bottlenecks.
- Applied Lean and SMED Principles to optimize tool storage and operation sequencing.
- Conducted Time Studies and Line Balancing to enhance throughput.
- Developed Power BI dashboards to track Key Performance Indicators (KPIs) .
- Supported plant layout redesign initiatives for enhanced process flow.
- Analyzed workflow inefficiencies and implemented effective solutions.
- Created Standard Operating Procedures (SOPs) and training materials .
- Conducted Performance Reviews , gave feedback, and set individual goals.
- Prepared operational reports detailing key performance indicators and production metrics.
- Maintained a clean, safe, and organized environment , enhancing team morale and productivity.
- Improved operational efficiency by adopting technology for Inventory Management .
Assistant Manager – IE
Aquarelle India Private Ltd
07.2016 - 05.2023
Process Optimization & Lean Implementation
- Developed and implemented production processes to maximize productivity and minimize waste.
- Partnered with management to create and deploy new methods, techniques, and equipment .
- Led cross-functional teams in applying Lean Manufacturing principles, enhancing efficiency and reducing waste.
- Conducted Time and Motion Studies to set standard production times and performance targets.
- Improved efficiency by managing KPIs , analyzing workflows, and optimizing space and equipment layout .
- Implemented 5S methodology to improve workplace organization, safety, and visual control.
- Facilitated weekly Kaizen events focused on setup reduction and material flow improvements.
- Managed Kaizen events that resulted in a 20% improvement in product quality and customer satisfaction .
- Introduced quality control procedures , significantly reducing defect rates and improving reliability.
- Ensured critical CTQ (Critical to Quality) procedures and high-risk elements were addressed prior to bulk production.
- Maintained Zero Surprises approach during changeovers, improving consistency and predictability.
- Analyzed process gaps and implemented multi-skilling strategies to improve operational flexibility.
- Trained cross-functional teams on Lean Principles , 5S , Standard Work , and Waste Identification .
- Led initiatives to promote a culture of continuous improvement across production teams.
- Created Value Stream Maps and implemented Pull Systems to improve material flow and reduce inventory.
- Developed detailed Production Timetables to optimize efficiency and reduce downtime.
- Prepared Operation Bulletins , planned manpower according to line plans and styles.
- Coordinated machinery, folders, and attachment planning to ensure readiness for production cycles.
Quality Controller
Webtech Autocom Engineering Private Ltd.
01.2013 - 01.2015
Quality Systems & Compliance
- Improved quality processes to enhance operational efficiency and product effectiveness .
- Updated Quality Control Standards, Methods, and Procedures to align with compliance and industry requirements.
- Maintained a robust Quality Management System (QMS) through continuous process reviews and improvements.
- Participated in product development meetings , contributing quality insights for new product introductions.
- Conducted thorough inspections of inbound and outbound products to ensure adherence to standards and customer expectations.
- Performed standardized tests on product samples to assess compliance with engineering tolerances.
- Checked production performance regularly to ensure conformity with process standards and specifications.
- Identified and escalated quality issues to management for timely corrective actions.
- Investigated non-conforming parts and led Root Cause Analysis (RCA) to address recurring defects.
- Analyzed production and quality data to identify trends and implemented proactive measures to reduce quality issues.
- Developed and maintained detailed documentation of quality checks , inspection records , and corrective actions for audit readiness.
- Oversaw the implementation of a Continuous Improvement Program , resulting in significant enhancements to product quality and customer satisfaction.
- Collaborated with cross-functional teams to initiate process improvements based on quality data and customer feedback.
Education
Bachelor of Engineering - Mechanical Engineering
A V C College of Engineering
Mayiladuthurai, India04-2013
HSE - Biology
St.Joseph's Higher Secondary School
Cuddalore, India05-2009
Skills
- Process Improvement & Lean Tools
- Process Optimization
- Lean Manufacturing & Kaizen
- Time and Motion Studies
- SMED Implementation
- Changeover Time Reduction
- 5S Workplace Organization
- Value Stream Mapping
- Visual Management
- Waste Reduction & OEE Improvement
- Process Mapping
- Downtime Tracking & Analysis Quality & Documentation
- Quality Control & Assurance
- Root Cause Analysis (RCA)
- FMEA (Failure Modes and Effects Analysis)
- SOP Development & Standard Work
- Pre-Production Planning
- Technical Documentation
- Continuous Improvement Initiatives Data & Reporting
- KPI Reporting & Analysis
- Inventory Management
- OEE (Overall Equipment Effectiveness)
- Data-Driven Decision Making Leadership & Collaboration
- Team Leadership
- Cross-Functional Collaboration
- Operations Management
- Customer Relationship Management (CRM)
Accomplishments
- 🏆 Emerging IE Award – Aquarelle India
Recognized for outstanding performance and innovation in Industrial Engineering. - 📜 Certified Quality Auditor – Arvind Limited
Successfully completed certification for quality auditing standards and practices in alignment with global compliance protocols.
Languages
Tamil
Bilingual or Proficient (C2)
English
Upper intermediate (B2)
Kannada
Upper intermediate (B2)
Hindi
Intermediate (B1)
Timeline
Assistant Manager
Arvind Limited
06.2023 - Current
Assistant Manager – IE
Aquarelle India Private Ltd
07.2016 - 05.2023
Quality Controller
Webtech Autocom Engineering Private Ltd.
01.2013 - 01.2015
Bachelor of Engineering - Mechanical Engineering
A V C College of Engineering
HSE - Biology
St.Joseph's Higher Secondary School
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