SIDDHARTH K SAJU
Mississauga,ON
Summary
Production management professional knowledgeable about allocating resources, optimizing production and increasing output with hands-on and dedicated approach. Articulate and professional problem-solver with good relationship-building abilities. Proficient in planning and implementing innovative production strategies.
Overview
9
9
years of professional experience
Work History
Production Manager / Toolroom Manager
Commercial Spring and Tool
12.2022 - Current
- The plant is Tire 2 automotive parts manufacturing company
- Facility is mainly focused on metal stamping, CNC-springs and weld assembly
- Specialized in manufacture parts for major OEMs and Tire -1
- Managing team of 3 supervisors and 100+ production working
- Responsible for production of 20 stamping presses, 15-CNCs, 20 assembly lines
- Doing production planning based on customer releases, forecast and routings
- We are IATF 16949 & ISO 9001 certified automotive stamping company
- Proper planning of shipment and scheduling pickup based on production lines
- Planning with shipping supervisor for 100% ON-time delivery and eliminate expediting
- Creates and fosters workplace culture centered on fairness and genuine care for employees, addressing all issues faced in production floor
- Ensuring production planning matches SAP production schedule and training supervisors to maximize use of ERP software
- Monitoring inventory based on SAP and trying to keep up with customer requirement
- Promote and sustain standardization of 1-pc workflow and improve cycle time
- Leads, manages, supports, and guides all department staff by setting clear goals
- Monitor and review performance and communicate effectively, and implementing on-the-job training and development plans
- Doing proper monitoring of OEE, weekly targets and setting up annual target plan
- Performing Kaizen trainings for employ's and promoting all employees suggestions
- Keeping track on employee performance review and monitoring everyday manpower with supervisor and ensuring everything stays in budget limit
- Implementing and training employees on process flow to improve production
- Ordering and monitoring of spares for dies, and making sure of not loosing any press time also giving feed back to the inside and out source die service team
- Working closely with in-die tapping unit team to adjust the program and enhance its longevity, also doing study on new tap for maxing efficiency
- Closely monitoring OT, weekend shift and productivity and review for each toolmaker
- Collect, measure and monitor data related to OEE of the department and implementing required modifications and upgrades as per market needs
- Facilitating active communication between every department and ensuring information and updates reaches each and every employee in the plant
- Taking customer demands under and working with die designing team on 3D & 2D
- Doing tooling modification to attain maximum stamping efficiency
- Do arrange team meetings and walk around production floor to keep good relation and getting information from employee's
- Monitoring proper allocation of department budget and doing requisition approvals
- Reporting to Plant Manager and VP regarding the issues or suggestion for attaining better productivity and implementing new methods and upgrades.
- Resolved issues quickly to maintain productivity goals and hitting above target.
- Managed multiple projects concurrently, ensuring timely completion and meeting budget constraints.
- Increased overall productivity by identifying bottlenecks in the production process and proposing effective solutions.
- Oversaw quality control efforts, maintaining strict adherence to industry standards and regulatory requirements while achieving high levels of customer satisfaction.
- Managed continuous improvement initiatives to drive gains in quality, flow, and output.
- Delivered direct feedback to senior management regarding project visibility and status.
- Reviewed maintenance and repair problems to determine appropriate action for resolution.
- Created streamlined production schedules and collaborated with production employees to communicate objectives and goals.
- Reduced waste and material costs by optimizing resource allocation and inventory management.
- Estimated labor requirements to support anticipated workload.
- Determined suitable crew requirements, scheduled employees, and worked with human resources to meet changing production schedules.
- Monitored team budgets to keep projects on task and avoid waste.
- Coordinated with sales and marketing departments to align production schedules with demand forecasts, maximizing both efficiency and customer satisfaction.
- Negotiated with suppliers for better pricing and terms, reducing overall procurement costs without sacrificing quality.
- Introduced automation and technological advancements to the production floor, leading to increased efficiency and reduced labor costs.
- Conducted regular performance reviews, identifying areas for improvement and implementing targeted developmental plans.
Production Manager
Kubota Material Canada
11.2020 - 10.2022
- We are OEM automotive manufacturing company
- Our facility has metal stamping press, Assembly lines, Manual Tig and Mig welding
- We do manufacture parts for oil and natural gas industry as well
- Excellent knowledge of business rules and procedures within the plant, including all manufacturing aspects from design to shipping and costing
- Good understanding of company policies and procedures
- Strong business knowledge and judgment to achieve goals and objectives
- Management, multitasking, time management, and organizational skills
- Financial acumen and project management skills
- Attention to detail and data processing skills
- Collaboration with various departments to ensure manpower, equipment, and materials meet production demand
- Ability to work under minimal supervision and handle pressure
- Supervision of equipment purchase, installation, and relocation, as well as layout planning
- Promotion of on floor Kaizen activities and ensuring safety talks and preventive maintenance are conducted, taking feed backs on the Kaizen activities
- Monitoring customer satisfaction, order status, and production scheduling
- Budget planning and utilization for the department and ensuring OEE is attained
- Participation in audits and safety incident investigations
- External visits to learn new processes and technologies for production enhancement
- Motivating the production team and encouraging their ideas for improvement
- Effective communication with customers and sales team for order management and scheduling
- Regular updates of production details in MS Office, Excel sheet, and ERP systems
- Identifying areas for improvement and implementing process enhancements
- Providing support to other teams when facing resource shortages or production challenges
- Managing scrap material and proper handling of documentation related to production processes
- Supervision of welding methods and equipment maintenance and purchasing
- Fostering a high-performance culture and talent development for the team.
Production Manager/Supervisor
ACG & Materials LTD
06.2017 - 11.2020
- ACG is major suppliers of gaskets and precision assembly part supplier to aerospace industry
- Production use different type of materials like metal, SS,HSC, polymers, HDPE, silicone, Acrylic etc.
- Production floor consist of different type of hydraulic presses, CNC Machine, 3-axis machining & laser cutting
- Facilitate daily shift meetings and communicate production schedules and manpower allocation
- Review production lines before each shift, gathering reports from previous shift supervisors and coordinators
- Create production schedules based on ship dates and manage raw material availability
- Address NCRs for quality issues and modify CNC programs for product quality
- Conduct time studies and root cause analyses to reduce machine downtime
- Encourage team collaboration for new ideas to reduce errors and production time
- Maintain communication with senior managers and project coordinators regarding schedules and job distribution
- Ensure proper maintenance and calibration of jigs and equipment
- Implement ISO/TS 16949 and ISO 14001 standards practically
- Provide proper training to new hires based on job requirements
- Enforce punctuality and discipline for team
- Coordinate with other departments to ensure smooth workflow
- Provide performance feedback and conduct appraisals for team members
- Foster good relations with customers and suppliers
- Ensure manufactured parts meet quality and aerospace standards
- Handle raw materials for aerospace projects with care and proper storage
- Train workers on FOD and efficient material use
- Oversee CFC for aerospace parts and prepare inspection reports
- Schedule machinery maintenance considering production and forecast
- Plan raw material availability based on forecast and production schedule
- Reduce production costs through work order combination and material planning
- Optimize work scheduling for maximum yield and reduced wastage
- Manage agency staff based on production demand
- Minimize overtime while maintaining production efficiency
- Maintain ERP and Excel records for production data and inventory
- Implement SPC methodology for quality control
- Conduct root cause analyses for any issues in quality or quantity
- Assist shipping team for smooth and on-time outbound shipments
- Ensure proper packing and labeling of aerospace parts
- Develop production schedules based on order history and market flow
- Monitor inbound and outbound processes to reduce shipment delays
- Plan advance purchases of raw materials to meet delivery times
- Conduct inventory inspections with materials handling department
- Implement corrective actions based on safety, quality, and other audits
- Perform safety audits and implement safety measures as required
- Order and manage inventory of metal sheets and other materials
- Update LN ERP, Sage 300, and Excel files for daily production details
- Manage employee schedules and vacations to reduce absenteeism
- Plan and direct efficient utilization of power tools, equipment, manpower, and material handling devices.
- Supported creation of detailed, technical financial models to value potential acquisition targets.
- Provided reporting for forecast analysis and ad-hoc reporting in support of decision-making.
- Created and managed project plans, timelines and budgets.
- Cultivated positive relationships with vendors to deliver timely and cost-effective supply of services and materials.
Department Manager
M&M Stamping
04.2015 - 05.2017
- Plant is based on metal stamping, Laser cutting, CNC machining, Forming and robotic and manual welding industry
- Plan and assign production schedules to meet customer satisfaction and delivery deadlines
- Lead and manage production team, including programmers, foremen, and quality assurance personnel
- Track operational data, time management, production records, and cost of production for progress evaluation
- Generate CNC programs using LaTeX software for Mitsubishi Lasers
- Modify AutoCAD drawings based on blueprint revisions and customer requirements
- Implement ISO/TS 16949 and ISO 14001 standards in practical execution
- Communicate production improvements to customers for on-time delivery
- Create efficient nesting/programming to reduce material usage, time, and manpower
- Monitor raw material inventory and forecast requirements
- Collaborate with the Plant Manager and supervisors to maintain final assembly ship dates
- Communicate with departments and make design adjustments to meet customer requirements
- Work with the Engineering Team on prototypes and make modifications to drawings
- Perform first-off and last-off inspections to ensure quality standards are met
- Design jigs for other departments based on material requirements
- Train new team members on machines and ensure compliance with health and safety regulations
- Maintain regular communication with supervisors and project engineers for planning and manpower allocation
- Adjust laser machine settings for maximum precision and perfection
- Prepare weekly production plans for lasers, CNC mills, and communicate with other departments
- Schedule machine maintenance and supervise proper inventory management
- Ensure received materials meet requirements and are organized and tagged appropriately
- Conduct monthly inspections and implement corrective actions for safety, quality, and other audits
- Set up and adjust lasers optics and optical systems as required
- Supervise manufacturing products and optimize production processes
- Orient, train, and coach employees and new hires
- Adhere to company policies and ISO standards
- Identify and eliminate interruptions and delays in production workflow
- Communicate with employees to gather suggestions, issues, and complaints to improve the workplace
- Manage hiring, transfers, and agency staff
- Supervise CNC mills/lathe, forging machines, and schedule Mitsubishi Lasers using nesting software
- Update MS Office and Excel with daily production details and weekly production schedules
- Report daily production and backlogs to the Plant Manager
- Manage workers' payroll and overtime, providing detailed reports to the finance department
- Maintain housekeeping of the production floor.
Education
Project Management Professional (PMP Certification) -
York
MIssissauga01.2025
Six-Sigma Green Belt Certification -
York
MIssissauga01.2022
P. Eng in Mechanical Engineering -
York
MIssissauga01.2025
ASQ Certified (American Society for Quality) -
ASME
MIssissauga01.2017
NDT - Level 2 Technician -
Kerala University
Mississauga, ON01.2015
Diploma in Mechanical Engineering -
Fanshawe College
London, Ontario02.2015
Bachelors of Technology in Mechanical Engineering -
Kerala University
MIssissauga06.2012
Skills
- 10 years of AutoCAD experience & 3 years in solid works
- ASNT Certified NDT-Technician for Quality (RT, PT, MT, UT, VI & FI)
- Proficient in Solid works 2015 & AutoCAD 2022, MASTERCAM, ANSYS, MS Office, RsLogix5000, K- pipe, Woodwoop, Lantex hand on experience, Microsoft Dynamics 365 (MD 365), Sage 300erp, Excel, Excel - Yamazumi charts, LN ERP, Kaizen, SAP-management
- ERP software's & Lean manufacturing experience, Production level loading, Root cause analysis, just in time manufacturing, Overall Equipment Efficiency, MRP, Purchasing, SAP-inventory and production managing
- Knowledge of IATF / TS16949 & ISO 90001
- Improved shipping ratio from 70% to 90% on-time delivery
- Brought back lot of works from subcon manufacturing
- Improved Inventory management and increased productivity and purchasing of materials
Languages
English
Full Professional
Accomplishments
- Reduced the stamping backorder (Spring & tool)
- Controlled the number of expediting shipments every month (S&T)
- Reduced the percentage of scrap and improved the quality of production (S&T)
- Improved the time management of team members and reduced the absenteeism (S&T)
- Improved shipping on time from 60% to 85% (KMC-Canada)
- Increase in daily productivity by implementing lean manufacturing methods (KMC-Canada)
- Reducing setup time & machining by introducing different machining techniques (All Companies)
- Implemented wending machine for supplying deliverables to workers (KMC-Canada)
- Reduced the excess inventory and implemented a pull system for more efficiency (KMC)
- Reduced backlog from 20 million to 5 million within 3 years (KMC-Canada)
- Reduced the scrap and increased usage of Raw material (ACG, M&M stamping)
- Implemented New shipping methods after discussing with customer (KMC-Canada)
- Reducing the overtime and ensuring the proper usage of machineries by level loading and extended shift of workers (KMC-Canada)
Timeline
Production Manager / Toolroom Manager
Commercial Spring and Tool
12.2022 - Current
Production Manager
Kubota Material Canada
11.2020 - 10.2022
Production Manager/Supervisor
ACG & Materials LTD
06.2017 - 11.2020
Department Manager
M&M Stamping
04.2015 - 05.2017
Project Management Professional (PMP Certification) -
York
Six-Sigma Green Belt Certification -
York
P. Eng in Mechanical Engineering -
York
ASQ Certified (American Society for Quality) -
ASME
NDT - Level 2 Technician -
Kerala University
Diploma in Mechanical Engineering -
Fanshawe College
Bachelors of Technology in Mechanical Engineering -
Kerala University
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