Elamurugu Velautham
Johor
Summary
Seasoned Senior Production Manager with comprehensive experience in overseeing manufacturing processes, coordinating teams, and improving efficiency. Strengths include strategic planning, quality control, and team leadership. Significant impact made in previous roles through successful project management, reduction of operational costs, and enhancement of overall productivity. Committed to fostering a productive work environment and achieving business objectives.
Overview
25
25
years of professional experience
Work History
Senior Production Manager
Dan Kaffe (Malaysia) Sdn Bhd
Johor
09.2021 - Current
- Develop and implement production strategies aligned with organizational goals
- Set production targets, budgets, and timelines to ensure efficiency and profitability
- Monitor industry trends and implement best practices to improve production processes
- Plan for capacity expansion or reduction based on market demand and business objectives
- Oversee the entire production process to ensure smooth operations
- Ensure production schedules are met while maintaining quality standards
- Monitor and optimize resource utilization (materials, labor, and equipment)
- Implement and maintain Standard Operating Procedures (SOPs) for production activities
- Ensure compliance with health, safety, and environmental regulations
- Ensure products meet quality standards and customer expectations
- Implement quality assurance processes and troubleshoot quality issues
- Collaborate with the quality control team to resolve defects or inefficiencies
- Conduct regular audits and inspections to maintain product consistency
- Lead, mentor, and motivate production teams to achieve targets
- Assign tasks and responsibilities to team members based on their skills and expertise
- Conduct performance evaluations and provide feedback to team members
- Identify training needs and organize skill development programs for staff
- Foster a positive and collaborative work environment
- Prepare and manage the production budget
- Monitor production costs and identify opportunities for cost reduction
- Negotiate with suppliers and vendors to secure cost-effective materials and services
- Analyze financial reports to ensure production activities remain within budget
- Identify bottlenecks and inefficiencies in the production process
- Implement lean manufacturing principles and continuous improvement initiatives
- Utilize data analytics and key performance indicators (KPIs) to drive decision-making
- Introduce automation and technology to enhance productivity
- Oversee inventory levels to ensure adequate raw materials and finished goods
- Coordinate with procurement and supply chain teams to ensure timely delivery of materials
- Minimize waste and optimize inventory turnover
- Prepare and present production reports to senior management
- Communicate production goals, progress, and challenges to stakeholders
- Collaborate with other departments (e.g., R&D, sales, marketing) to align production with business needs
- Identify potential risks in the production process and develop mitigation strategies
- Ensure business continuity by planning for equipment failures, labor shortages, or supply chain disruptions
- Ensure compliance with local, national, and international regulations
- Promote sustainable practices in production to reduce environmental impact
- Maintain proper documentation and records for audits and inspections
- Stay updated on advancements in production technology and equipment
- Evaluate and implement new tools or systems to improve efficiency
- Drive innovation in production methods and product development
- Address customer complaints related to production issues
- Collaborate with stakeholders to meet delivery deadlines and quality expectations
- Build strong relationships with suppliers, vendors, and internal teams
- Ensuring adequate scheduling of staff
- Heading new project development and improvement projects
- Completed the installation and commissioning of the new roasted whole bean packing line
- Improved the efficiency of the free-falling evaporator by 50% by implementing a proper preventive maintenance program
- Reduce manpower for manual blending process 50% through inline blending system
- Zero complaint achieved on metal dust in spray dry powder by implementing magnet trapping system in spray dry line
- Zero complaint achieved on leaking and stain issue during bulk bag packing by improving the filling design hood
- Improvement of plant GMP by creating a dedicated cleaning crew
- Improved warehouse forklift breakdowns & accident by 80%, done modification and speed reduction
- Implemented Warehouse Management System which increases the stock accuracy to 98%
- Completed upgrading the new Ice con plant, improve efficiency by 250%
- Improved the interlock system to reduce coffee wastages during production
- Zero cases of coffee accidentally transfer to drain after implementation
- Water saving 90% (65-80 m³) for sealing water vacuum system per day by modifying the cooling system for free falling evaporator PHE
Production Manager
Haco Asia Pacific Sdn Bhd
Selangor
12.2014 - 09.2021
- Monitor daily production output to meet the targeted Overall Equipment Efficiency (OEE) for all the packing lines
- Direct and coordinate the packaging operations ensuring that objectives are met in a timely and cost-effective manner
- Provide leadership and development to achieve company goals and objectives
- Exercise control over operating expenditures and labor costs
- Maintain safe, reliable plant facilities and equipment
- Implement and maintain cleaning and sanitizing programs
- Provide direction, development, training, and leadership to Shift Managers, Senior Operators, and Production Workers
- Evaluate, troubleshoot, and improve on packaging section systems and processes
- Monitor performance and lead corrective action teams
- Ensure that all plant safety procedures are adhered to
- Coordinate with Sales and Marketing on the inventory level to ensure continuous supplies to the customer are maintained
- Troubleshoot issues related to the quality issue and provide a solution
- Solved high coliform counts in Food Service plant finish product by implementing proper GMP procedure and air conditioning system
- Successfully implemented the stock control system in the Food Service plant to reduce wastages due to expired stock and improve the stock accuracy by transferring the stock control management from warehouse to production
- Powder in seal issue for stick packing line solved by changing the auger design which has reduced the material wastages and eliminated the usage of ground sugar which have a higher cost
- Successfully installed the step seal system for the Latte stick packing line which reduced in 35% manpower utilization
- Improvement in stick packing line efficiency by 30% with the implementation of an online packing system
- Improved the speed of the Starbucks pouch line by 7% by implementing the single pull system
- An increment of 1,200 pouches a day
- Improved the Manual Packing line output by 50% by implementing the bag change over system
- Increase of 5MT packing per day
- Passed the exam for Radiation Protection Officer and accepted the additional task given to be the company RPO
Factory Manager
Universal Nutri Beverage Sdn Bhd
05.2014 - 11.2014
- Oversee daily manufacturing processes, ensuring efficient production schedules and meeting output targets
- Monitor quality control to adhere to food safety standards (e.g., HACCP, GMP, ISO 22000) and product consistency
- Implement process improvements
- Ensure compliance with local, national, and international food safety regulations
- Manage certifications and prepare for audits by regulatory bodies
- Oversee allergen control, cross-contamination prevention, and accurate labelling (nutritional info, allergens)
- Recruit, train, and supervise employees, including shift workers, sanitation crews, and QA personnel
- Conduct regular safety drills and hygiene training
- Foster a culture of safety and accountability, emphasizing PPE and GMP (Good Manufacturing Practices)
- Manage raw material procurement, storage, and perishable inventory to minimize waste
- Liaise with suppliers for timely deliveries and negotiate contracts
- Optimize stock levels using inventory management systems to prevent shortages/spoilage
- Develop budgets, monitor expenses, and identify cost-saving opportunities (e.g., energy efficiency, waste reduction)
- Analyse production data to optimize resource allocation and reduce overheads
- Schedule preventive maintenance for machinery to avoid downtime
- Ensure rigorous sanitation protocols to meet hygiene standards (e.g., CIP systems, pest control)
- Drive eco-friendly practices: waste recycling, water/energy conservation, and sustainable sourcing
- Develop contingency plans for recalls, equipment failures, or supply disruptions
- Lead rapid response to incidents, ensuring transparent communication with stakeholders
- Address customer complaints related to quality or delivery
- Collaborate with R&D on new product development and marketing teams for launches
- Integrate automation, IoT, or AI to enhance efficiency and traceability
- Stay updated on industry trends (e.g., smart packaging, blockchain for supply chain transparency)
- Ensure occupational safety compliance (OSHA standards) and emergency preparedness (fire drills, first aid)
- Monitor workplace conditions to prevent accidents or contamination risks
- Work with sales teams to forecast demand and adjust production schedules
- Manage shelf-life testing and coordinate with logistics for timely distribution
- Maintain records for audits, including batch tracking, sanitation logs, and employee training
- Ensure traceability systems are in place for rapid recall execution if needed
Factory Manager
Network Foods Industries Sdn Bhd
Selangor
08.2013 - 04.2014
- Provide leadership for the successful day-to-day operation of the facility
- Work closely with quality personnel to review product consistency
- Review established production schedules for all manufacturing departments to maintain the established inventory levels are met while operating at the highest efficiency possible
- Coordinate the hiring and training of all manufacturing personnel
- Monitor operation expenses and research ways to reduce costs while maintaining product quality
- Work closely with the Environmental Health and Safety team to ensure all members of the manufacturing team are aware of safety policies to provide a safe workplace for our employees
- Maintain Inventory levels and control the flow of products
- Maintain and support a superior safety and housekeeping program, including all timely communication initiatives
- Develop and execute the plant manufacturing budgets
- Analyze workforce requirements
- Conduct performance appraisals and provide coaching and guidance to all operations employees
- Encourage and promote operating in a continuous improvement environment
- Remove production constraints; allocate human and equipment resources and direct production employees to attain all established goals
- Remove waste and constraints from the production process to improve efficiencies and enhance productivity
- Communicate with research and development as well as product management personnel to develop new product strategies
- Coordinate the relationship with our union workforce force and negotiate union contracts as needed
- Maintain security system and access readers
- Involve in forwarding purchasing of raw materials based on the market price
- Monitor the major maintenance upgrade and automate the plant facilities to meet the company objective
- Successfully reduced the labor cost by systematic planning and introducing new labor contractors at a cheaper rate
- Successfully maintained the wastage of raw materials and packaging materials below the KPI level
- Set up a planning system that enables the user to plan more efficiently
- Successfully reduced the wastage of one of the packaging machines from 40% to 12% by improving the key line of the packaging
- Reduction in electricity cost by 7% by improving the output
- Increased the chunkies packing machine output by 50% by implementing online packing from packing machine to pouching machine
- Reduced labor cost by 30%
Production Manager
Network Foods Industries Sdn Bhd
06.2010 - 08.2013
- Responsible for the day-to-day management of the chocolate manufacturing plant and R&D
- Responsible for overall Good Manufacturing Practise in Production & Production Planning
- Responsible to ensure compliance to Quality Management System and HACCP requirements
- Responsible to fulfil Marketing needs and customer satisfaction
- Responsible for production performance including capacity planning, productivity, quality, safety, and continuous improvement strategies
- Responsible to monitor, organizing, and managing resources and implementing action plans to ensure optimum efficiency for Plant operation
- Responsible to drive and seeking improvement in labor productivity, materials usage, and value improvement projects
- Responsible to determine labor, materials, and equipment requirements for smooth operations
- Ensure proper operations of all manufacturing facilities, troubleshooting repair, and maintenance of plant and machinery
- Responsible for the maintenance of production records and providing periodical reports such as daily, weekly, and monthly as and whenever required
- Responsible to conduct regular production meetings, troubleshooting, and decision making
Production Manager
Emperor's Kitchen Sdn Bhd
10.2007 - 06.2010
- Company Overview: (Food Manufacturing)
- Responsible for overall Good Manufacturing Practise in Production & Production Planning
- Responsible to ensure compliance to Quality Management System and HACCP requirements
- Responsible to fulfil Marketing needs and customer satisfaction
- Responsible for production performance including capacity planning, productivity, quality, safety, and continuous improvement strategies
- Responsible to monitor, organizing, and managing resources and implementing action plans to ensure optimum efficiency for Plant operation
- Responsible to drive and seeking improvement in labor productivity, materials usage, and value improvement projects
- Responsible to determine labor, materials, and equipment requirements for smooth operations
- Ensure proper operations of all manufacturing facilities, troubleshooting repair, and maintenance of plant and machinery
- Responsible for the maintenance of production records and providing periodical reports such as daily, weekly, and monthly as and whenever required
- Responsible to conduct regular production meetings, troubleshooting, and decision making
- (Food Manufacturing)
- Reduced manufacturing cost by introducing new suppliers with lower prices, reduction of 10% for major raw materials
- Reduction of the labor cost within 6 months by implementing proper production planning and control
- Manage to transfer the whole production to the new plant without interrupting the supplies to the outlet within the time allocated
- Reduce the production hours of paste manufacturing by a total of 2 hours per batch by introducing a new machine
- Reduction of 60 production hours per month
- Reduce the processing hours for the raw materials by introducing a new cutting machine
- The total reduction of 192 production hours per month
- Implemented the wastage monitoring system and manage to reduce the wastage of the raw materials within the management KPI
- Implemented a systematic production planning program with excel which manage to calculate the labor and material usage for the whole month
- Key person in the design of the customized material planning, warehousing, and account MIS system
Q.C & R&D Officer
KFC (Peninsular Malaysia) Sdn Bhd
Selangor
01.2000 - 09.2007
- Production, planning, and control of three departments, i.e
- Coleslaw Production, Garden Salad Production, and Pizza Hut Salad Bar Vegetables
- Manpower planning for the departments
- Maintaining the P&L of the department
- Maintaining the quality and the safety of the product produced
- Implementing and maintaining the YUM! Brands International Quality System and Food Safety System
- Implementing and maintaining the GMP and HACCP
- HACCP coordinator for the department
- Research and development of new products
- Handling customer complaints
- HALAL certificate application and maintenance
- Have succeeded in reducing the microbe count in Coleslaw to an acceptable level through modification of the production process
- Implemented 7 days shelf life for Garden Salad through modified atmosphere packaging hence reducing production working days to 6 days a week
- Have implemented the HACCP and GMP system for the processing line
- Certified in HACCP, ISO 9001:2000, and GMP
- Certified lead auditor in HACCP
Education
Master's Degree - Food Technology
University Putra Malaysia
01.2023
Master's Degree - Business Administration
University of Ballarat Australia
01.2006
Bachelor's Degree - Food Technology
University Sains Malaysia (USM)
01.1999
Skills
- Advanced Production Planning and Control
- GMP
- Food processing
- Food manufacturing
- Food Quality Control
- HACCP
- X-ray radiation safety
- ISO 14000
- ISO 22000
- Halal Management System
- Operations management
- Cross-functional collaboration
- Quality control
- Staff management
- Problem solving
- Budget management
- Data analytics
- Capacity planning
- Manufacturing operations
- Continuous improvement processes
Additional Information
Certified Class 3 Radiation Protection Officer, Lifetime member Malaysian Institute of Food Technologist, Member Malaysian Board of Technologist, Member Malaysian Radiation Protection Association, Leadership charisma, Dynamic team player, Sense of responsibility, Highly inquisitive, Creative and resourceful, Excellent skills in communication and collaboration
Languages
- Bahasa Malaysia, 10, 10
- English, 10, 10
- Tamil, 10, 3
Languages
Tamil
First Language
English
Advanced (C1)
C1
Malay
Proficient (C2)
C2
Timeline
Senior Production Manager
Dan Kaffe (Malaysia) Sdn Bhd
09.2021 - Current
Production Manager
Haco Asia Pacific Sdn Bhd
12.2014 - 09.2021
Factory Manager
Universal Nutri Beverage Sdn Bhd
05.2014 - 11.2014
Factory Manager
Network Foods Industries Sdn Bhd
08.2013 - 04.2014
Production Manager
Network Foods Industries Sdn Bhd
06.2010 - 08.2013
Production Manager
Emperor's Kitchen Sdn Bhd
10.2007 - 06.2010
Q.C & R&D Officer
KFC (Peninsular Malaysia) Sdn Bhd
01.2000 - 09.2007
Master's Degree - Food Technology
University Putra Malaysia
Master's Degree - Business Administration
University of Ballarat Australia
Bachelor's Degree - Food Technology
University Sains Malaysia (USM)
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