Vikas Mulay

• Enhanced inventory accuracy through systematic cycle counts and enforced accountability across plant-level inventory processes.
• Improved cycle count adherence based on ABC classification, aligning with defined schedules for inventory accuracy.
• Implemented aging inventory control and developed a liquidation strategy to manage obsolete or slow-moving stock at the plant level.
• Led staff welfare initiatives, including training programs, morale-boosting activities, and employee engagement plans.
• Ensured adherence to inbound processes including Goods Receipt Note (GRN) creation, physical verification, discrepancy reporting (short/excess), and CTQ part validation by the Quality team before storage.
• Executed efficient put-away processes using SAP WMS and HHT devices, with strict adherence to accuracy and system discipline.
• Managed internal replenishment processes between plant storage locations to ensure smooth material flow.
• Conducted 100% put-away audits to eliminate errors and ensure accurate material placement within the warehouse.
• Led storage layout optimization projects based on revised material min-max levels and production forecasts.
• Improved workplace visual management and implemented OPLs (One Point Lessons) to enhance operational efficiency.
• Fostered a strong safety and quality culture by addressing unsafe acts/conditions and encouraging kaizens, suggestions, and continuous improvements.
• Coordinated material line delivery to production areas through SAP WMS pull system to ensure timely availability.
• Monitored and maintained consumable materials to avoid stockouts and ensure production continuity.
• Ensured strict adherence to FIFO (First-In-First-Out) and FEFO (First-Expired-First-Out) processes to maintain inventory integrity, reduce waste, and ensure timely usage of materials based on shelf life or expiration.

· Achieved DTS more than 99% within 7Hrs. (No of lines received/no lines Put away done

· Production Control Support : Monitor & achieved 100% on time Move Order picking & Kitting activity.

· Monitor & drive the material delivery Trolley maintenance & Modification activity with third party vendor & get it close on time, No escalation from production.

· Promoted safety policies and practices among personnel, enforcing appropriate handling and use of equipment and products. 100% Compliances.

· Kept storage areas organized, clean, and secure to fully protect company assets. All Capex Audit.

· Drive & achieved the more 99.9% inventory accuracy at warehouse with help of cycle count, empty bin audit, right part right locator audit, put away audit. Net

· Improved the All SOP's of every process, VSM & SIPOC.

· Implemented the Visual factor at site with locator one point lesson, training plan, manpower rotation, area owner concept.

· Drive & review the MHE maintenance with third party vendor, total 21 MHE (reach truck, forklift, stacker, etc.)

· Drive indirect material procurement. Initiated PR/PO for indirect material like as stationary, MHE spear part etc.

· Drive Root Cause Analysis/CAPA for defect delivery or avoid the reoccurrence defect/NC.

· Managed BA resource allocation & legal compliance.

· Built motivated warehouse team to consistently accomplish operations goals and exceed performance targets.

· Daily morning review with production team for production plan.

· Drive and review KANBAN, Two Bin delivery method.

· Audit & review the shelf-life part and action plan.

· Review & drive on time Repro movement in SAP. (Stock transfer shop to shop)

· Review & Drive daily MIS report to concern team.

· Review & drive daily on time Min level report shared with respective buyers & update the shortages for production line.

· CAPA for production losses due to material delivery or material shortages.

· Elevated team performance with motivational approach and excellent training abilities.

· Organized shift meetings to communicate and resolve issues for night operations.

· Followed implementation of new processes, collaborated with stakeholders and tracked progress.

· Maintained tidy and organized warehouse environment to comply with cleanliness standards.

· Double checked records, daily reports, and inventory transactions to identify and correct variances.

· Attendance Review & Review Picking planning as per WMS control board

· Review all the Pendency MO (Material order) and clear all transaction, Review the Defect tracker, Review Store area 5S

· Review daily all MHE check sheet (RT,BOPT,FLD), Asset review.

· Unsafe act and unsafe condition reports & meeting with MHE operator.

· Kaizen preparation & weekly process training to team.

· Review RCA (Wrong, Short part, Damage) update the defect tracker.

· Productivity Review Report & warehouse Dashboard report share to team.

· Planned optimal workflow through successful scheduling and task delegation.

· Maintained attractive, clean and fully stocked store environments to maintain appeal for every customer.

· Elevated team performance with motivational approach and excellent training abilities.

· Coached staff to leverage upselling and cross-selling opportunities, driving consistent sales by cultivating competitive and results-driven culture.

· Materials receiving, storage and issuance as per production plan, above 98% achieved KPI score every month. No Production Loss due to non-issue of materials in time. Quarterly inventory, Zero discrepancy in the stock levels.

· Morning review with PPC for daily plan & communicated to team for on time material delivery to production line.

· To prepare MILKRUN CALL UP on weekly basis with the help of PPC team. Maintain inventory as per vendors capability of providing material, Follow-up with transport team(TVS Team) and Vendor team for pick up related issue

Co-Ordinate with logistic person for transport arrangement. Take feedback from customer for FG receipt status, Planning for Dispatch, container availability, material availability as per schedule,

· Worked with team to identify areas of improvement and devised solutions based on findings.

· Implemented the 100% PFEP.

· Conduct the daily cycle count audit & communication with finance for discrepancy clear in system.

· Analysis of shortage parts, coordinate annual physical inventory. Monitor daily parts count & found discrepancy. Space Management & Rearrange location as per requirement. Daily MIS report circulation to concern persons on time. Ensure Returnable/ Expandable dunnage clearance on time, Ensure MHE Verification & Maintenance on time &Trolley TPM schedule.

· Rejection review & communication to vendor.

· Built strong relationships with customers through positive attitude and attentive response.

· To prepare the cycle count schedule base on ABC classification.

· Conduct the cycle count as per schedule.

· Daily to report to inventory Coordinator & review with discrepancy item.

· Prepare the Miscellaneous report to finance for stock adjustment in system.

· Managed cycle counts on raw materials, packaging supplies and completed products.