Kuresh Hathiyari Seeking a challenging opportunity as a Plant Manager to impact bottom line using Lean Manufacturing, Six Sigma, Servant Leadership, Supply Chain and Supervisory Principles League City, TX 77573 kuresh.hathiyari@gmail.com 281-229-4265 • Over 16 years of work experience in manufacturing industries (Semi-Conductors, Lens Making, Oil and Gas) • Managed a plant and warehouse/yard with 100 plus employees • Skilled in managing/coaching people through servant leadership, setting expectations and holding people accountable • Six Sigma Black Belt certified and implemented ISO 9001-2015 in plants • Lean Manufacturing certified and completed several lean diagnostics for various sites • Lead multiple Kaizen events, A3’s, Toyota Kata principles with focus on Process/Value Stream Mapping, Cause and Effects Matrix, Ishikawa, non-value-added transportation and waste elimination projects • Led and completed multiple six sigma and lean manufacturing projects, capital projects and numerous MIS projects • Skilled in software related to Design, Statistics, Operations Research, DBMS and Microsoft applications • Excellent communication skills both verbally and written • An effective project champion/team leader/team player and able to multi-task with focus on SMART goals • Benchmarked best practices/methods through other plants and implemented them through projects Authorized to work in the US for any employer Work Experience Plant Manager Shawcor Inc (SCL.TO) - Pearland, TX February 2019 to April 2020 • Developed and executed a plant vision and strategy to lead a team of 100 plus employees in a highvolume manufacturing facility spanning over two plants and two shifts for pipe coating (FBE, ARO and Concrete Weight Coating) • Reduced OSHA recordable rate by 66% for the 2019 calendar year by executing a culture focused on improving the safety performance by reporting heavily on the leading indicators such as near misses, hazards and behavior-based observations driven by the workforce • Engaged the team in solving problems on the floor using A3’s and Kaizen events striving for continuous improvement on rework rate due to coating defects • Managed and drove P&L excellence on a daily level focusing on labor optimization, reduced material variance, scrap and variable cost reduction initiatives. Reduced variable cost by 20% as a percentage of revenue due to these efforts • Developed team members by enabling their decision-making process, holding their initiatives accountable and leveraged talent to capitalize on their strengths internally and externally • Improved equipment reliability by 25% in 2019 calendar year by focusing on the top ten un-planned downtime reasons communicated in the daily management meetings and cascading a TPM approach to floor level. Identified budgets for preventive maintenance activities and locked in repair initiatives • Improved first pass quality by 10% by identifying defects at the source, engaging front line supervisors and workforce in problem solving those defects at the source rather than stockpiling Plant Superintendent/Operations Manager Greif Inc - Baytown, TX November 2014 to February 2019 • Managed 29 employees directly (Customer Service and Warehouse) and 54 employees indirectly (Production, lab and Maintenance) and overseeing floor operations to generate $7.2 Million in annual operating profit for the plant for 2018 Fiscal year • Interfaced with vendors, customers, corporate support resources (safety, quality, sales and engineering) to support operations • Coached and challenging employees to seek solutions to daily operational issues and using lean manufacturing principles to problem solve • Established capital budgets for the plant, and ensuring operating budgets are met for labor materials and other variable cost items for the plant as defined in the S&OP for the fiscal year • Ensured employees adhere to all safety, quality and efficiency policies and metrics for the plant Lean Manufacturing Manager Greif Inc - Deer Park, TX February 2011 to October 2014 • Conducted Lean Diagnostics in various Grief plants to identify opportunities worth $10 Million in operations • Supported various site managers in implementing equipment efficiency software to manage their site's downtimes and uptimes on equipment • Implemented individual projects within sites identified from the Operational Excellence Diagnostics with site leadership and site personnel • Supported and led the center of excellence for implementing a Lean program within the site with focus on efficiency Essilor of America Inc(EPA: EI Stock Traded in Paris) Manufactures semi-finished polycarbonate lenses for Optics/Rx through injection molding process Methods Engineer Essilor of America, Inc. - Dudley, MA November 2006 to February 2011 • Implemented 5S and visual controls in the polarized business unit and achieved $41,000 savings through material supplies validated by finance • Implemented best practice of lens inspection methodology. Realized 4% inspection yield improvement due to a paradigm shift of change in inspection methodology • Assisted the team in establishing visual aids to avoid mis packs of lenses at packaging. This helped in reducing Mispack ppm from 367 to 47 in a span of 7 months. Received award from the customer for a methodical project approach using the six sigma DMAIC system • Industrialized an automatic inspection machine and automatic lens cutting machine from concept through development, pilot, and production acceptance to sort lenses thus removing subjectivity from human inspection. Enabled reduction of 8 FTE's saving $320,000 annualized • Developed a detailed plan for the finishing area thus enabling reduction of FTE's by 65% and increase throughput by 35% Custom Sensors and Technology (Kavlico Corp, Schneider Electric Inc Manufactures pressure, position, force, tilt and level sensors (transducers) for automotive, aerospace & military purposes, power generation, HVAC/R, engines and industrial vehicles Six Sigma Project Engineer/Black Belt Custom Sensors and Technology (Kavlico Corp, Schneider Electric Inc - Moorpark Park, CA August 2004 to October 2006 • Improved yields on Traction weld pressure port to housing tube line from a baseline of 83% to 97% thus realizing $653,000 in a span of 9 months: Tools Used: Process Mapping, Hypothesis testing, Ishikawa and design of experiments • Reduced warranty claims from 2-5 claims a month to almost zero (ppm of 1500 reduced to 50) Tools Used: Root Cause Analysis, 8D's, Corrective action seven step procedure • Created a balanced score card for the organization linking all department metrics to key performance indicators for the organization to achieve the vision mission and values for the corporate • Reduced failure analysis turnaround time from 37.2 days to 7.7 days by identifying non-value added activities. Tools used: Time value map, Cell Layout, Kanban system and Value Stream Mapping • Improved global yields for dual brake sensor at Ambient, HOT and End of Line calibration stations from 87% baseline to 98% realizing $81,000 annualized return on investment Research Analyst Boeing Aircraft Company - Wichita, KS January 2003 to May 2004 * Examined and analyzed torso kinematics of the back motion variables of the operator performing manual material handling task in virtual and real environments. * Presented this research as a paper in the 8th Annual International Conference of Theory, Applications and Practice in Las Vegas, Nevada in Nov 2003 and in the Winter Simulation Conference held in Orlando, Florida 2004 (http://www.wintersim.org/abstracts04/VR.htm) Production Engineer Deccan Bearings Ltd - Mumbai, Maharashtra January 2001 to July 2001 * Updated PFMEA on bearing components and inspected raw materials such as outer ring, inner ring, cages and rollers using Gage R & r techniques, and process control charts such as Bar and R. Responsible for day to day procurement of bearing components * Improved the Cell Line layout for subcontracting processes such as forging•annealing•turning•heat treatment•grinding using lean manufacturing principles Production Engineer Asian Containers & Virat Industries Ltd - Mumbai, Maharashtra July 1999 to May 2000 Bombay, India Manufactures aluminum collapsible tubes for toothpastes, pharmaceutical creams and aluminum containers for bottle sprays(perfumes and pesticides) Production Engineer: July 1999- May 2000 * Conducted time and motion study for steps involved in the extrusion machine as it was the bottleneck * Maintained levels of raw material inventory for slugs, coatings, inks and caps using ABC analysis Education Master of Business Administration in Business Administration University of Houston, C.T Bauer College of Business August 2016 Master of Science in Industrial Engineering Wichita State University - Wichita, KS May 2004 Bachelor of Science in Production Engineering Mumbai University - Mumbai, Maharashtra May 1999 Skills • • • • • • • • • • • • • • • • • • • • • • • • • ACCESS (4 years) ACCESS 97 (4 years) DATABASE MANAGEMENT SYSTEM (5 years) DBMS (4 years) EXCEL (10+ years) Lean (10+ years) 5S (10+ years) Six Sigma (10+ years) Root Cause Analysis (10+ years) Lean Manufacturing (10+ years) Plant Management (5 years) Manufacturing (10+ years) SAP (2 years) Kanban Project Engineering Project Planning Value Stream Mapping Minitab ISO 9001 Production Management Process Improvement ERP Systems Project Implementation Visio Tableau Links https://www.linkedin.com/in/kuresh-hathiyari Assessments Mechanical Knowledge — Expert April 2020 Understanding and applying mechanical concepts and processes. Full results: https://share.indeedassessments.com/attempts/ c7689838855bdf65ff3cb42a3c826653eed53dc074545cb7 Work Motivation — Highly Proficient April 2020 Level of motivation and discipline applied toward work Full results: https://share.indeedassessments.com/attempts/ c24dbb4cfc1904f7afadd6d3b01420d9eed53dc074545cb7 Management & Leadership Skills: Planning & Execution — Proficient April 2020 Planning and managing resources to accomplish organizational goals. Full results: https://share.indeedassessments.com/attempts/ ff94e87f0d00d18f67fb1c5d999a7108eed53dc074545cb7 Management & Leadership Skills: Planning & Execution — Proficient April 2020 Planning and managing resources to accomplish organizational goals. Full results: https://share.indeedassessments.com/attempts/ ff94e87f0d00d18f67fb1c5d999a7108eed53dc074545cb7 Logic & Critical Thinking — Expert April 2020 Using logic to solve problems. Full results: https://share.indeedassessments.com/ attempts/208c1b9472e0504001e3f32d8881657deed53dc074545cb7 Analyzing Data — Highly Proficient May 2020 Interpreting and producing graphs, identifying trends, and drawing justifiable conclusions from data. Full results: https://share.indeedassessments.com/ share_to_profile/4de8142414237cfe4b2e8e6b049ec571 Work Style: Conscientiousness — Proficient May 2020 Tendency to be well-organized, rule-abiding, and hard-working. Full results: https://share.indeedassessments.com/attempts/ c7689267f629321b87aa9f13dc59b506eed53dc074545cb7 Indeed Assessments provides skills tests that are not indicative of a license or certification, or continued development in any professional field. Additional Information COMPUTER SKILLS * Statistical software: Minitab 15, SPC XL, * DBMS: MS Access 97/2000, * Operating systems: Windows XP/2010 * Applications: Microsoft Word, Visio, Office, Excel, Project and PowerPoint
