Sivakkumar - Certified Independent Director, Caresoft Global I Ex Ford I Ex CAT/CGN

Experience

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  Wonjin Autoparts Pvt ltd

  Oct 2009 - Feb 2010

  Management Trianee

  Project leader responsible for handling engineering projects and managing global clients. Plan and execute projects from initiation to closure, develop strategies to deliver project within schedule and cost.Key Functions:  Co-ordinate PPAP submissions to customers on new products. Follow up with material orders to ensure timely delivery and within Budget. Identifying and managing project risks and prepare/ implement risk mitigation plans Develop and manage the project schedule and cost throughout the project. Excel at stakeholder communication Responsible for framing project charters, project plan, dashboards, budget Vs schedule and gate reviews Show less

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  CGN & Associates/Caterpillar

  Feb 2010 - May 2013

  Lean Sigma/Supply Chain Consultant

  Identify process gaps and implement realistic solution using Lean and Six Sigma tools. Develop effective and efficient Supply Chain processes. Identify potential project opportunities.Project 3: Value Stream Transformation – Supplier development Walk through the Value Stream to perform VA –NVA analysis; Implement Kanban by designing a FIFO (pull) system to optimize the material flow, reduce inventory and do line balancing. Address quality/capacity issues by Identifying and eliminating root cause by implementing lean six sigma  Created supply chain should costing model through value chain analysis to find actual cost–$1.5M/vendor saved Performed Cost-Benefit analysis for C class parts to maximise cube utilisation Reduced machine change over time by 40% using 5s and SMED.Project 2: Implement Continuous Improvement tools during Facility Construction Analyse the processes from suppliers to customers, design AS-IS and TO-BE flows. Improved warehouse and production NVA operations. Develop logistic cost performance metrics.  Driven replenishment planning through S&OP meetings with demand/manufacturing planners Design work station layouts for efficient process, machine allocation and material handling. Semi-automate assembly lines – Delivered on time with $0.2Mn saving Vs plan Added 2+ days of production capacity by implementing product sequencing model. Project 1: Adopt efficient packaging and create pricing structure for CAT – DC, Japan Evaluate & optimize all the shop-floor materials based on usage/ location to reduce material shortage lag time Conduct time/motion study on packing actions to benchmark with best practices  Design new process/ re-engineer existing process to improve efficiency, service level & reduce operational risks Rationalized packaging by reducing 25% containers used. Introduced the use of rebuilt drums, thereby creating a leaner and more sustainable supply chain, resulting in an immediate savings of $ 90,000 Show less

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  Ford Motor Comapany Pvt Ltd.

  Jun 2013 - Mar 2017

  Senior Supply Chain Executive - Global Capacity and Constraints Management

  Worked in Advanced Manufacturing environment with strong background in Supply Chain Management, Inventory, Planning and Supplier Management. Develop and manage the global supply chain network for key commodities, drive optimization, deliver Lean/Six Sigma projects to enable continuous improvement on productivity, quality and cost. Perform demand Vs capacity analysis.Key Functions:  Develop demand plan, lead S&OP and maintain optimised inventory across the APAC region using “Kinaxis” Perform work through major ERP systems like Inventory Management, Manufacturing and operations Review demand/ capacity data for power train commodities, identify/resolve potential bottle neck with suppliers Coordinate shipments with suppliers, 3PL & regional supply chain team to ensure on-time material availability Develop Premium Freight Budget and optimise it by proactively identifying potential constraints well ahead Work closely with Finance operations to identify top 20% high supply chain cost challenges and opportunities by product by route to market. Lead projects to remove waste from supply chain Evaluate vendors 14 months prior to find various investment requirement to support future demand/new launch Lead new tool (Kinaxis) implementation from launch till user validation and support process redesignAchievements:  Resolved 14+ part constraints through inventory transfer, capacity uplift, network optimising etc. - $13M+ saved Developed algorithm to find potential auto part constraints 3 months earlier – 28% production impact reduced Developed automated shipment plan tool to use during part shortage - Ease part allocation between mfg plants Trained 100+ employees on continuous improvement tools through corporate training programs Show less

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  Hallmark Securities

  Mar 2017 - Nov 2017

  Operations Manager - Supply Chain Management

  Lead a new investment project to set up and optimize the supply chain network for service parts. Develop and execute part specific demand Plan and inventory plan to enable organization meet sales and service objectives. Key Functions:  Supply Chain (SC) PMO to lead the Program Management Office (PMO) and work closely with clients SC teams to define the value chain strategy, S&OP process and SC performance metrics Collaboration with key business partners and stakeholders to implement lean supply chain network Analyse and establish the key material flow parameters such as order quantity, lot size, frequency, and replenishment interval to support business requirements. Identify risks and develop effective mitigation plansAchievements:  Recommended supply chain network improvement opportunities for a vendor – potential cost savings ($0.9M) Removed 3 Distribution Centres from sourcing list to direct shipments from origin – 4.2 weeks lead time reduced Show less

• 

  Caresoft Global

  Nov 2017 - now

  • Benchmark best-selling vehicles like Tesla Model Y, Renault 5, and 4 Chinese Vehicles to offer best in class ideas leading to add new Features, Cost Saving design which provides edge on Market Positioning• Manage system wise Tear Down (BIW, Thermal, Power Train, Electrical etc) to understand their uniqueness in assembly• Display parts and conduct Exposition for Client teams to help them understand the unique design of Benchmarked vehicles• Drive standardization to reduce overall cost of manufacture, reduce time to design, improve serviceability, enhance the customer experience, and increase consistency of current and new products.• Segregate MBOM vs EBOM and arrive at In-House assembly parts. Perform Line Balancing by station to achieve best throughput• Achieve 30% Cycle Time reduction and 20% Manufacturing Cost reduction through module-based manufacturing• Identify, prioritize and drive product cost reduction initiatives with Product Design team, “Should Costing” team and Vehicle Tear down team.• Drive and develop a sustainable VAVE & LEAN culture through efficient Benchmarking Sessions • Identify risks, document, prioritize, mitigate, and communicate. Show less • Set up & Govern PMO. Create a detailed project plan to Consolidate 3 Plants (Mexico, China, Surat) in Chennai – India. • Co-own S&OP meeting with Sales Managers to understand Forecast; accordingly deplete the Inventory at China and Mexico• Coordinate with Machine Suppliers, Operations, Logistics, Contractors & Admin team to ensure all the machines are shipped on Time, Factory is set up based on the agreed layout. Also, oversee all govt approvals are sought on time• Apply Lean Practices and support process automation; resulted in 6% Lead Time reduction and 8.5% Cycle Time Reduction • Lead PMO and Business Intelligence (BI) team to establish the standard process across services and measure the KPI’s continuously. • Perform feasibility analysis on different services to develop and Implement New tools to ease data capturing• Improve Operational and Billing efficiency by analyzing large data using statistical techniques to draw actionable inferences• Work with Finance team to understand the opportunities involved (within each services) to reduce the cost 'through various measures like Capacity Utilization, Infrastructure utilization etc• Identify and Explore process Improvement opportunities• Develop dashboards for various services using Qlik Sense (BI Tool) to enable easy understanding of Data and to Monitor the performance Show less

  • Senior Manager - Manufacturing Engineering

    Jan 2020 - now

  • Project Manager

    Nov 2017 - Jan 2020