KARTHIK BALU
Regional Manager – Head of Plant Operations
Over 19 years of valuable experience and driving all phases of plant Operations, Quality, Safety, Project Management, Lean Manufacturing, Costing, Change Management, Business Support Services & developments, Facilities Control, Resource Allocation management and people
PROFILE SUMMARY
• Enterprising Leader skilled in collaborating with cross-functional teams, implementing efficient workflows, and driving continuous improvement initiatives to enhance productivity, quality, Safety and profitability
• Strong background in strategizing operational policies & supply chain functions for the industry, defining risk mitigation tactics and deploying systems for the smooth running of operations and site’s redevelopment
• Proven success in coordinating project tasks, maintaining project documentation, communicating with stakeholders, and assisting project managers in various administrative tasks
• Knowledge Expert: Business Operations Expert, Lean Manufacturing Specialist, Steered Efforts maintaining the cost in operations. New Product Development, Analytical and Technical skills to enhance the plant's productivity and Problem Solving
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EDUCATION
2023-24
Senior Management Program – IIM (Indian Institute of Management)
2016
MBA in Operations Management, Madras University
2011
B.Tech. in Mechanical Engineering, SRM University
2008
Diploma in Production Management, NILEM
2004
Diploma in Automobile Engineering, HIET
CORE COMPETENCIES
Plant Operations Management
Corporate Financial Reporting
Strategic Planning & Execution
Leading Highly strategic Projects (PMP)
Change Management Initiatives
Business Support Services
Global Value Creation
Supply Chain Management
Strategic Human Resource Management
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SIGNIFICANT ACCOMPLISHMENTS
• Concluded 230B projects whereby the product quality improved after its failure in LVPT trials by Toyota India; the project was sustained in Autoneum; contributed towards obtaining position in top 5 Lean Manufacturers out of 39 Autoneum companies (created the lean visionaries for the entire plants)
• Crucial in maximizing profits and acquiring monthly turnover from $3million to $4million through optimization of equipment management and expense valuation
• Succeeded Quenching Heat Exchangers Cleaning for Sabic Affiliated refinery for Yanpet & Ibnrushd while receiving appreciation for the same from client Best Hydro Jetting
• Issued the certificate of Appreciations for Excellent performance and outstanding support during the event of Petrokemya Plants Mega turnaround for the year 2022
• Awarded as a best Operating Engineer for the QA problem solved
• By team efforts contributed towards the improvement of “Pitch-Time” in Conveyor Line, cycle time was reduced and shift output was increased from 426 (60Secs) to 511 (50secs)
• Accomplished Benchmark Cell of Balanced Cycle Time and JPH (34pcs/hr.) for international projects (oversees Calsonic Kansei Companies Japan)
• Victoriously minimized cycle time from 92 to 72 secs, reduced process time and increased velocity that accelerated floor carpet productions from 300-400(nos.) & enhanced productivity through Robot Water Jet Cutting
KNOWLEDGE PURVIEW
Lean Tools | Toyota Production Systems (TPS) - Single Minute Exchange of Die (SMED), Overall Equipment Efficiency (OEE), Value Stream Mapping (VSM), Total Productive Maintenance, (TPM) Pull Systems, Kanban systems, Supermarket, Muda Walks, Obeya Board, Kaizen, Line Layout Design, Suggestion Systems, JishuKen, Levelling, Heijunka & Jishu Hozen, Just in time (JIT), Maintenance Performance Metrics, SWC/SCT- Human & Machine Movement Analysis, 5S & 3C
Quality: Statistical Process Control (SPC) | Quality Management System & Total Quality Management (TQM) | ASES- Nissan Quality Systems | Quality Circle, Problem-Solving technique
Supply Chain Management: Sales & Operation Plans, (S & OP), Master Production Schedule. Delivery PPM, Inventory Management
Project & Program Management: Extensive Knowledge in PPAP, APQP, PFMEA, and Control Plan
Human Resource: Basics of HR –Statutory Compliance (Factory Act, Labor Act, ESI, PF), Key Performance Indicator (KPI), Planning and Implementing Training plan with HR department
WORK EXPERIENCE
2018 – 2023| Axis Inspection Contracting JSC, KSA - Manufacturing & Industrial Maintenance Division
PLANT OPERATION – Responsible for Six Plants
Key Result Areas:
• Ensured consistently High Level of Performance in plant operations, Turnover & safety compliance Leading a massive team of 360
• Expert in driving business excellence and experienced in leading business improvement programs delivering significant increases in revenues and cost savings
• Expertise at managing an entire breadth of supply chain operations inclusive of Procurement, Sourcing, Material Management, Cost Settlement and Component Development
• Driving the company’s operating capabilities to surpass customer satisfaction and retention, and company goals
• Expanding business operations through strategic negotiations and project expansion initiatives
• Recruit, employing various initiatives to coach employees to optimize their capabilities and review their performance
• Enhancing facility safety and security measures, ensuring compliance with industry standards and regulations
• Implementing innovative administrative systems, processes, contributing to overall business growth and success
• Shaping the work Environment and creating strategic vision for the organizations
2011 – 18| Production Manager | Autoneum Nittoku Sounds Proof Products Pvt. Ltd., India
Joint Venture of Swiss cum Japanese Manufacturers of Automotive parts (NVH) for leading Car Manufacture Known as Renault Nissan, Toyota, Ford, Hyundai and Maruti Suzuki
Key Result Areas:
• Responsible for Overall Production, New Products Developments, Process Engineering, Tool Developments, Cost Reduction and Lean Concepts Implementations
• Proven success in achieving reduced Assembly Line Takt, Material Movements, Process Time through Facility Development/Layout Modification, Capacity Analysis, New Machine & Method Study installations and Work Measurement
• Managing Budget, Projects, People, KPI for entire plants and Maintenance Systems Implementations
• Identified Certified Trainer and implemented training plan with HR Department to the plan personnel
• Localization of part/RM procurement which were being purchased from China & Thailand
• Transacted skills in Tool Commissioning at Suzhou Hongyangyu Mould co. Ltd., China (Jan’17).
• Successfully executed Greenfield projects automations for new projects especially for K2 models of Nissan Cars developed as Robot Waterjet Manufacturing and Pressing machines.
• BOM Optimizations: Executed cost reduction projects & resource utilizations improvement and administered high-volume manufacturing of more than 120 products
• Liable for operating Lean Audit at Asia level (Overseas) - Taichung & Tianjin Plants, China and India
2009 – 11| Senior Engineer | Calsonic Kansei Mother Son Ltd., India (Japanese Joint Venture)
2004 – 09| Operating Engineer | Mando India Ltd., India (Korean Joint Venture)
TRAININGS & CERTIFICATIONS
• Entrepreneurship Development Institute Certifications at Hindustan University by Government of India| 2004
• Anand University – Basic Technical Knowledge, Behavioral & Attitudinal Education, In-plant training for one month | 2005
• Certificate of Appreciation for Cricket at Calsonic Kansei Motherson | 2011
• Lean Manufacturing | 2010 & Leadership Development Program | 2013
• Certificate of Excellence – Internal Quality Auditor Training (IATF ISO/TS16949:2016) | 2015
• Safety & Environment Education | 2013
• Toyota Production System Training (3 days) | Toyota India | Apr 2013
• Lean Manufacturing Implementations Training at Turkey in Autoneum Bursa Plants (Overseas)- Material Management, MPS, Pull flow, Waste Management, SOS, S& OP | 2016
• Autoneum: Competition Law: Preventing Anti – Competitive Practice | Preventing Bribery and Corruption | Preventing the Phishing | Cyber Security Awareness | 2016 -2018
• HR & Statuary Compliance & Contractor Compliance Audit Certified | Maxwell Consultancy | 2012
• PMP: Project Management Workshop Training | 2019
• Certifications on Project Management “Agile Essentials: A Practical Guide to the Agile Process” | 2023
PERSONAL DETAILS
Date of Birth 5th March 1984 || Languages Known: English, Hindi and Tamil
Passport Number & Validity U0056951 / 20th October 2030