Sasikumar Raji

Experience

• 

  TVS Motor Company

  Jul 2004 - Apr 2008

  Module Lead

  Spearheaded team of 100 operators and 6 Team Leaders to deliver production plan from vehicle assembly conveyor.

• 

  Caterpillar Inc.

  Apr 2008 - now

  Leading a diverse cross-functional team in managing Operation, Purchase, SCM, Product and Process Quality, New Business development, Sales, Finance and Accounting processes of the Hose Assembly Plant (Vector Hydraulics Private limited – JV of Caterpillar India). Accountability also includes delivering on the annual Business Plan and Operational performance including managing the 3PL & Global supplier bases and driving efficiency improvement projects across the value chain.Notable Accomplishments• Led the team as a Facility Manager for the transformation projects and delivered the OPACC of $ 100 K (Layout Optimization, Capacity Addition, Process Efficiency improvement, Operating & Finance Cost reduction)• Improved the Safety & Quality performance by driving the Safety Culture and Robust Process improvements resulting in getting the Supplier Excellence Level in Global platform by Caterpillar among few. • Developed a Strategy for Business initiatives such as Vertical integration, Expanding footprint and Value added services to improve the revenue and profitable growth of organization• Successfully established the robust supply network for Direct and Indirect Purchase of materials, Transportation and Freight management, resulting in a $50K cost reduction and improved delivery and quality performance. Show less Work Profile – Leading a diverse team of 350+ employees and cross functional team in managing Operation, Manufacturing quality, and Shipment process of Off Highway truck and Large Mining truck assembly. Accountability also includes delivering on annual operating budget management of $5 Mn, managing Union & 3PL supplier performance and driving efficiency improvement projectsNotable Accomplishments• Led the team as a process owner for the Value stream transformation projects and delivered the OPACC of $ 2.2 mn (6 RIW, 1 GB Project, 2 BB Projects, 28 OIA Projects)• Improved the Safety performance by driving the Culture of Safety principles and leading the team on ZIP (Zero Incident Performance) Projects on theme like Back up wrench elimination, Man machine interaction, Pinch point elimination, Point of operation / Guarding and Hammer elimination.• Driven the lean deployment and maturity improvements to gain operational excellence in BIQ (Defect reduction by 68%), RPRT (RTS Adherence by 55%), SLT (Throughput time by 48%), MU (Designed head count ratio by 32%) • Led the capacity prove out projects by focusing on Modularity, Line balancing, H2K replenishment, Material presentation improvement & Change management concepts • Led the Operation team to Establish & Prove the New Large mining truck assembly line by Working with NPI & CFT team to meet the customer demand and with CPS & APQP aligned vision. Show less Work Profile – Led 180 employees in a team managing Site Logistics Dock to POU (Inbound), Warehousing, Inventory Management & Governance, Production Scheduling, and Supply chain planning with 3PL supplier performance and driving efficiency projects.Notable Accomplishments• Sponsored the team on Logistics Warehouse transformation 6 sigma project, focusing on Information, Material and Process flow. 100% MM parameter validation (SLT, SS, LE, MBQ, LS, GR Lead time), Improved the Part density (25%), touches (22%), Ton meters & Material presentation (60%), Power BI Dashboard for Analytic visualization. • Established a robust and sustainable Plan for every part (PFEP) refreshment strategy by focusing on data elements in terms of adequacy and accuracy, digitalization & Visualization with automated information flow• Implemented the designed Manpower Standard through MOST Study for Logistics Processes resulting in transaction cost reduction Show less Work Profile – Leading different cross functional teams across business unit to deliver the strategy, Lean, 6 sigma & Value stream transformation projects deliverables & driving the learning and development culture in the organization as coach for Black belts & Green Belts Lead projectsNotable Accomplishments• Certified 6 Sigma and Lean (CPS) Black Belt with 20 DMAIC & 3 Value stream transformation projects• Led the Factory level Value stream transformation project (Dock to Shipment) covering the entire OTD process resulting in Capacity, Throughput time, Safety & Quality culture improvement• Led the Safety, Quality transformation projects in assembly & Painting operation to deliver the zero-defect process with in built safety by adopting the lean and CPS principles• Led the Port Capacity enhancement, Configuration rationalize and Throughput time reduction projects to meet the customer availability with shortened lead time• Led Supply chain transformation projects that includes implementation of Facility Make/Buy strategy & Total cost of ownership studies for different modular assembly• Led the Service model for entire logistics operation in factory (First of kind in CIPL India)• Worked with Multinational Diverse team (Indonesia, Russia & US) for improving the facility product quality & Supply chain OTD process set up with IECC Show less

  • Facility Manager - Caterpillar JV Company (Vector Hydraulics)

    Jul 2023 - now

  • Factory Operation Manager at Caterpillar Inc

    Jan 2022 - Jul 2023

  • Factory Logistics manager

    May 2020 - Dec 2021

  • 6 Sigma and Lean Black Belt & Strategy Manager

    Jul 2017 - May 2020

  • Group Manager Supply chain Warehouse and Logistics

    Apr 2014 - Jun 2017

  • LTDP – Leadership and Technical Development Program – Order to Delivery function

    Apr 2010 - Mar 2014

  • Section Manager

    Apr 2008 - Mar 2010