Rajesh Nandula

RAJESH NANDULA
Lean manufacturing, Operational Excellence
rajesh_nandula2004@yahoo.com
9686288963.

Experience (21 years – 1996 to 2017) – Manufacturing Operations

Plant Head - Operations - Group Manager at Aditya Birla Group, Bangalore,
September 2010 – till date(7 years)
Group Manager - Manufacturing Operations. Green Belt &Black belt six sigma expert. Certified assessor for Business excellence Aditya Birla Excellence Framework. Green field project Leader.IMS Lead auditor ISO 9001 ISO 14001 EMS ISO 18001 OHSAS

Handled two factories – one in Karnataka with 800 manpower and 11 lines of Casual and Formal Trousers & another new project in Tamilnadu with an expansion capacity of 4000 manpower and 24 lines in two shifts - following Aditya Birla’s World Class Manufacturing Framework.

Green field project Leader. Aditya Birla Fashion and Retail Ltd (ABFRL) will set up an apparel manufacturing unit in Odisha with a capacity of 2.5 million pieces per annum. The foundation stone for the unit was laid by Odisha Chief Minister who applauded the group for the initiative.
We are proud to bring the manufacturing of apparels for our premium brands like Louis Philippe, Van Heusen, Allen Solly and Peter England to Odisha as part of 'Make in Odisha' initiative. The ABFRL Bhubaneswar unit is the first manufacturing unit outside Bangalore. "Our unit will have the capacity of 2.5 million pieces per annum and generate employment for about 1,600 people, most of whom will be women.

Brands Handled: VHVanHeusen, LP Louis Philippe, LY Louis Philippe Young, AS Allen Sollyand Peter England.

Responsible and Accountable for the activities of the Factory from Cut-to-Ship along with factory related pre-production activities and general administration of entire factory. Lean System: Ensuring the functions as per Lean Manufacturing System Ensuring 6 S sustainability in Factory Ensuring Lean activities by working with Kaizen Promotion Team and Continuous Improvement Group Administration: Maintaining Visual, Social and Technical Compliance at Factory General Maintenance of Electricity, Machines and Utilities. Material Management - Receipts from H.O., Storing and Issues. Co-coordinating with the H.O. Administration dept. for various requirements. Responsible for the Safety of the Building, Plant & Equipment, Materials, Accessories etc., Maintain proper record of Raw-material and Garment for in-coming, out-going, In-process, rejections, scrap, rectification etc., and maintain traceability in case of need. Production: Receive the Production Order (P.O.) from the H.O. Liaison with H.O. regarding P.O. related activities. Participate in the Pre-production Meetings. Discuss with Floor Managers and others concerned and prepare Production schedule. Co-ordinate with Sub-contract Jobs, Embroidery work, inter-factory work, washing work etc. Organize Raw-material and plan for the cutting of the Fabric to feed the Sewing line / Batch. Co-ordinate with Production Manager and organize for the right material at right time with right quality and quantity for delivery as per schedule. Organize& Co-ordinate complete Dispatch/Delivery/Shipment work. Maintain uniform flow of Garment in the Finishing section and Packing section as per the priorities assigned by the Head Office. Organize required Manpower and right machinery and associated accessories in the Cutting, sewing and finishing sections. Co-ordinate with the concerned Merchandiser to ensure the production bulk is as per the Buyers requirement and organize to carry out the necessary changes / modifications as and when required and record modifications. Quality: Ensure that the Finished Garment for the Buyers Q.C. Inspection and get their approval before dispatch. Take steps to avoid rectification, rejection, scrap, loss to company, theft etc., and optimize resources. Co-ordinate with Quality Head and guide him and get all the Quality related job (Inspection&system) done through him. For Raw-material as well as Garment.. Take necessary corrective action based on feedback from Quality Head. Assist, guide, and support Quality In charge to necessary action with related to quality issues. Ensure Sample Approval - Fabric, Sample Garment, and Trims& Accessories from concerned. Pilot lot procedure follow up.. Packing approval follow up. General Supervision: Co-ordinate with the Buyers representative, Buyers Q.C. representative etc., and understand their requirement and take necessary action to implement them. Exercise cost control measures wherever applicable. Follow the Head-Mfg. / CEO instructions and report to him the day to day happenings. Attend to Jobs / follow instructions. Conduct daily meeting (for 10 minutes- Lean Requirement) with staff and communicate about the happening and discuss about the priorities, preferences, problems etc.,. Ensure Manpower Plan and Recruitment as per the plan Developmental Activities: Involve in factory developmental activities such as Continuous Improvement System, Kaizen Promotion, New Innovative Initiatives which will help to increase productivity, improve Quality and ensure Compliance

Certified assessor for Business excellence - Aditya Birla Excellence Framework covering:
Leadership , Vision, Mission, values and Ethics, Championing Organizational Change, People Empowerment, Sustainability, Excellence in Project Execution, Strategic Plan Deployment, Strategy Development, Strategy Deployment & Review, Enterprise Risk Management, Enablers, Work Environment, Organized Work place, Environment, Health and Safety Management, Infrastructure and Asset Management, Infrastructure management , Asset Maintenance System, Ownership Culture , Supply Chain Management, Business partners/ service providers / suppliers engagement, Operations management, Supply Chain Integration, Customer Experience Management, External customer orientation, Internal Customer orientation, Quality Management, Quality Planning, Product/service/process Management, Extension of Quality Management to suppliers / customers / expansion projects, People Management & CSR Initiatives, Employee Relationship Management, Performance management , Competency building and training, CSR Initiatives, Information and Knowledge Management, Metrics Management, Information Management, Knowledge Management, Systematic Improvement and Innovation, Improvement opportunities and problem solving, Employee Involvement in Continuous improvement, Creativity Management, Technology Management, New Product Development, Technology Implementation / Absorption, Technology up gradation, Business Results , Financial Results, Business Growth, Key Performance Indicators (QCDIP), Quality, Cost, Delivery, Innovation, Productivity , Sustainability, Customer Engagement Results, Internal Customer Satisfaction - Perception Measurement trends , External Customer Satisfaction -Performance Indicator Trends, People Engagement Results, Employee Satisfaction Perception Measurement Trends, Employee Satisfaction Performance Indicators Trends , CSR Initiatives Results, Society’s Satisfaction on CSR: Perception Measurement of initiatives, Society’s Satisfaction on CSR: Performance Indicators of initiatives, Suppliers Engagement Results, Service providers/ suppliers perception Measurement, Service providers/ suppliers performance Measurement.





Plant Head - Operations ( Lean manufacturing ) at Gokaldas Exports, Bangalore
2009 - 2010
Expert in LEAN MANUFACTURING. Lean concepts - Policy deployment, Value stream mapping, Waste
elimination, Value add vs Non Value add, Lean production systems, SKB (Shop floor Kaizen Breakthrough)
event, MDI (Managing for Daily Improvement) events, TAKT time, Single piece flow, Hour by Hour
charts, Develop opportunities, Developing a Kaizen plan, JIT principles, Value chain map, Set-up reduction
methods, Create PULL using Kanban tools, Production Smoothing, Mixed model production, Sigma Kaizen,
TPM, SQDC - safety quality delivery cost, Jidoka, Pokayoke, Standard operations, DMAIC.

Products Handled : MEXX brand Casual and formal trousers and shirts.

General Manager - Operations at BanswaraSyntex, Surat , Gujarat
2008 - 2009
PRODUCTION - Woven formal trousers. KRAs: Responsible for CUT to PACK. Formal trousers for
buyers; # Formal trousers for buyers like Hunter apparel solutions Ireland Garda, Lillotex , Defecto ,
Dunnes stores, Oxford ,Max holdings land mark , korovesis brothers , kosmidis Greece, Perry ellis , Grand
national, Virginian school wear, Dragosp zoo Poland , Potter heimtextilien home furnishings Germany etc.
Implementation of 5S. Factory in SEZ zone - Apparel park - Surat, Gujarat.

Factory Manager - Operations at Ambattur Clothing International, Bahrain
August 2000 - November 2008 (9 years)
FACTORY - Woven formal structured trousers. KRAs: Managed the setting up function of the new 600
m/c trouser manufacturing unit for the company's branch at Bahrain. Conducted training program for the
local laborers on various activities involved in the manufacturing process. Responsible for the machine
installation and trial run of the same in the new factory. Knowledge of all activities involved such as factory
planning, men machine ratio, 4 point fabric checking , fabric shrinkage & pattern selection, lay planning ,
table planning, 10 line issue plan, line production, style layouts, line balancing using balancing matrix &
flexibilitymatix, manning using SAMs, re- engineering, quality assurance, washing, trimming, checking
with DHU, pressing , packing and container loading.

Asst. Factory Manager - Operations at Ambattur Clothing Ltd, Chennai
Page2
August 1999 - July 2000
FACTORY - Woven shirts. KRAs: Responsible for the setting up of a new 150 m/c shirt manufacturing unit
and preparing layouts for all the departments. Recruitment of man power, handling machine installations,
fixing targets, sampling . Responsible for designing the work aids to increase productivity, training and
implementing SPC system for the quality assurance.

PRODUCTION EXECUTIVE at AMBATTUR CLOTING LTD
August 1998 - July 1999
Responsible for the production and quality control activities of one line consisting of 60 machines. Handled
most of the international brands.

MANAGEMENT TRAINEE at AMBATTUR CLOTING LTD
August 1997 - July 1998
REENGINEERING - Woven shirts. KRAs: Trained by KSA - KURT SULMON ASSOCIATES -
AMERICAN CONSULTANT and KSA TECHNOPAK in Reengineering of shirt manufacturing unit.
Sampling and preproduction comments Operation sequence , Layout , Manning Design of work aids Method
and Time study Line balancing Trained by TIMOTHY BUMBORGH ( QUALITY CONSULTANT ) in SPC
- STATISTICAL PROCESS CONTROL Training SPC coordinators and Inline checkers.

LECTURER at SRM ENGG COLLEGE
August 1996 - July 1997
KRAs: Lecturer for theory, engg drawing and practical classes for 1st year and 2nd year students of
Mechanical engg. dept. of SRM engg. college in Chennai.


Skills & Expertise
Textiles
Manufacturing
Apparel
Team Management
Sourcing
Kaizen
Six Sigma
Quality Assurance
Value Stream Mapping
Lean Manufacturing

Education

MBA Degree in Operations Management in ICFAI
Master of Business Administration (MBA), OPERATIONS MANAGEMENT, 2013 - 2015
Grade: A Grade

Certificate in Business Basics in ICFAI
Page3
Certificate in Business Basics, Operations Management, 2013 - 2014
Grade: A

Diploma in Management in ICFAI
Diploma in Management, Operations Management, 2013 - 2014
Grade: A

Post Graduate Diploma in Operations in ICFAI
Post Graduate Diploma in Operations, Operations Management, 2013 - 2014
Grade: A

MBA General Management in Global Nxt University, Kuala Lumpur, Malaysia
Master of Business Administration (MBA), GENERAL MANAGEMENT, 2012 - 2014
Grade: A Grade

Training in Lean manufacturing, Re-engineering,
1996 – 2014

BE Mechanical in SRM University Chennai
BE, MECHANICAL, 1992 – 1996

Infant Jesus Matriculation Higher Secondary School Chennai

St Mary's School Chennai

Rajesh Nandula - Professional Interests:

· Consultancy for setting up of a new manufacturing unit – Investigation phase, Pre-implementation phase, Operational phase and Realization phase of the new project.

· Consultancy for Setting up of Operational excellence framework for any organization - that covers comprehensively all aspects of manufacturing excellence.

· Consultancy for BPR (Business process reengineering) - aims to help organizations to fundamentally rethink on how they do their work in order to dramatically improve customer service, cut operational costs and become world class competitors.

· Consultancy for Lean Six Sigma – aims to improve performance by systematically removing waste, combining lean manufacturing and Six Sigma to eliminate the eight kinds of waste (muda): Transportation, Inventory, Motion, Waiting, Over production, Over processing, Defects and Skills.

· Consultancy for Apparel manufacturing offering full service (End to End solutions) for the fashion industry.