Hari Raj Kumar
Nilai
Summary
Accomplished Manufacturing Manager with a proven track record at BCS Integration Solutions Sdn Bhd-Daifuku Oceania, transforming operations and achieving a 30% cost reduction. Expert in production management and lean manufacturing, demonstrating exceptional problem-solving abilities and leadership. Skilled in fostering high-quality standards and efficiency, driving significant improvements in production and cost savings.
Overview
31
31
years of professional experience
Work History
MANUFACTURING MANAGER
BCS INTERGRATION SOLUTIONS SDN BHD-DAIFUKU OCEANIA
01.2021 - Current
- Focused management role whereby handled manufacturing and assembly plant
- This plant consists of 8 assembly lines and 1 manufacturing line
- The total number of staff is 80, with a mix of local contract staff at a 70:30 ratio
- There are 15 management staff members, including managers and engineers
- Responsible for delivering a production value of 15 million monthly to major airport baggage systems worldwide
- Successfully orchestrated the transformation of a 36,000 sqft factory into a cutting-edge 112,000 sqft facility, encompassing:
- Strategic sourcing of the facility
- Streamlined manpower restructuring from management to production staff
- Thorough machinery valuation and setup
- Comprehensive plant layout planning, including contractor sourcing
- Precise capacity calculation and planning
- Efficient warehouse planning and setup
- Secured essential approvals from relevant government bodies
- Successfully managing the profit and loss statement within the allocated budget, keeping costs under control and maintaining a strong bottom line
- Cost-saving activities such as optimizing packing material and reduced 30% from the initial cost savings up to RM 1.2 million within two years
Operations and Marketing Manager
MBf Printing Industry Sdn Bhd
01.2017 - Current
- Focused management role - handling production which consist of 15 lines with headcount of 120 at factory and line and 3 management staff
- Delivering for export 15 containers/week/Handling production capacity of 6.5million per month
- Improvement plan called 'MARUTEKI'- reduce downtime, optimize run rate and high-quality assurance
- Achieved 80% efficiency and meet high demand from Japan and Korea for McDonald's Food industry
- Reduced overheads by 15% by reducing wastage and maximizing manhours
- Handles marketing to meet all project schedules and control budgets accurately with only 3 staff in the department
- Develop and coach procurement, store and logistics teams to drive Production KPIs
- Total control of production planning to follow through with operational excellence and continuous improvement plans by each project
- Some other improvement plans carried out include Kaizen, Lean Sigma, 5S and others as required by projects
- Key projects include - Production index up by maximizing number of cavities/ups, increased by 15%
- Reduced wastages from 3% to 1.5%
- Manpower management - Retrained Frontline operators to manage down time
- Cost Saving Improvement-Merged color management by using more of CMYK compositions
- Planning-Merged generic runs within sku's to reduce set up hours and wastages
Assistant Manager Production
MBf Printing Industry Sdn Bhd
01.2011 - 12.2017
- Overall management of daily production planning as an assistant to the Plant Manager
- Decision making involves raw materials management to efficient production output, Lean Production with focus on hygienic manufacturing
- Additional roles include training operators, technicians and supervisors in AIB (International Standard for food packaging requirement)
Production Planner
Georg Jordan (MALAYSIA) Sdn Bhd
01.2010 - 12.2010
- Company Overview: (A subsidiary of Georg Jordan, Germany- manufacturer for electrical insulators & power panels)
- Focused on implementing goals by production planning and monitoring adherence by departments on policies, SOPs and affect changes as required for improvement
- (A subsidiary of Georg Jordan, Germany- manufacturer for electrical insulators & power panels)
Assistant Production Engineer cum Process Controller for Glass Fibre Plant
NIPPON ELECTRIC GLASS (MALAYSIA) SDN BHD
01.2001 - 12.2009
- Company Overview: (A subsidiary of NEG, Japan- manufacture of glass fiber, Cathode Ray Tubes, lighting applications and heat-resistant glass)
- Focus on establishing operational best practices and champion standardization and innovation in operation at XX (number) plants in Shah Alam
- Manage smooth daily production operations meeting yield and cost reduction targets by monitoring closely machinery reliability while supporting QA and R&D processes
- Key responsibilities include ISO 14001 internal auditor
- As Key Pioneering Project Team for transfer of technology, underwent training over 3 months at NEG, Notagawa Plant, Japan
- Responsible for Set up, and management of systems, SOPs and regulation adherence according to state government requirements
- Strong skills in operation and maintenance of batching plant, furnace, feeders, bushings, winders, cutting machines and weighing and packaging machines
- Excellent skills and knowledge in process flow of glass fiber from melting to labelling for export by region
- Led a team of 50 in project implementation and operation and maintenance
- Received the Managing Director's Silver Medal Award for innovation
- (2008) for Material Glass Recycling System (MGRS) Reduce cost of materials by 70% and increased recycling of process waste from 15 tons per month to 120
- (A subsidiary of NEG, Japan- manufacture of glass fiber, Cathode Ray Tubes, lighting applications and heat-resistant glass)
Junior Process Controller
NIPPON ELECTRIC GLASS (MALAYSIA) SDN BHD
01.1995 - 12.2001
- Company Overview: (A subsidiary of NEG, Japan- manufacture of glass fiber, Cathode Ray Tubes, lighting applications and heat-resistant glass)
- (A subsidiary of NEG, Japan- manufacture of glass fiber, Cathode Ray Tubes, lighting applications and heat-resistant glass)
Process Technician
NIPPON ELECTRIC GLASS (MALAYSIA) SDN BHD
01.1994 - 12.1994
- Company Overview: (A subsidiary of NEG, Japan- manufacture of glass fiber, Cathode Ray Tubes, lighting applications and heat-resistant glass)
- (A subsidiary of NEG, Japan- manufacture of glass fiber, Cathode Ray Tubes, lighting applications and heat-resistant glass)
Education
Bachelor Degree of Science - Mechanical Engineering
University of Rockhampton
United States01.2011
Executive Diploma - Double Major in Engineering & Business Management
Universiti Teknologi Malaysia
01.2008
Skills
- Production Management Quality
- IT and Machinery skills
- Costing & Finance
- Professionalism
- Problem-solving
- Organization efficiency
- Knowledge of applicable federal, state and local laws and regulations
- Communication skills
- Daily production planning
- Raw material procurement scheduling
- Process improvement
- Quality Assurance (QA)
- Logistics
- Training of operators
- Training of technicians
- Training of supervisors
- 5S
- ISO 9001
- ISO 14001
- ISO 18001
- Production improvement plans
- Systems
- Policies
- Procedures
- Regulation adherence SOPs
- Machinery operation
- Maintenance of APG machines
- Mold maintenance
- Raw materials batching machines
- Yield improvement
- Cost reduction targets
- IT skills in production and process monitoring systems
- Operations management
- Lean manufacturing
- Master scheduling
- Business development experience
- Material handling expert
- Engineering/project management experience
- Health and safety compliance
- Fabrication professional
- Assembly line production
- Quality assurance authority
- Safety and quality standards
- Priority management
- Extremely quick learner
- Continuous improvement
- Strategy alignment
- Goal achievement
- Troubleshooting specialist
- Cost reduction strategies
- Safety protocols
- Scheduling and forecasting
- Certified manufacturing manager
- Manufacturing technologies
- Production scheduling
- Production planning
- Process scheduling
- Customer support
- Sheet metal installations
- Value stream mapping
- New employee hiring
- Lean manufacturing techniques
- Statistical process control
- Production procedures
- Forecasting
- Waste reduction
- Internal auditing
- KPI tracking
- P&L management
- Product development
- Effective Budget Planning
- Brand-building strategies
Languages
- Excellent English
- BM
- Japanese
Personal Information
Nationality: Malaysian
Training And Professional Development
- 2019, Stress Management
- 2018, Saphira Coatings, High Impact Selling Skills
- 2017, Masterclass-Practical Managerial Skill for Production Managers, Efficiency Management at Production, 5S Management @ Workplace
- 2016, BRC Issue 5 HACCP Requirements, FSC Chain of Custody and Systems Development, Safety Management @ Workplace
- 2015, BRC/IOP Global Standards, Managing Employment Issues @ Workplace, Internal Auditor for BRC/IOP Global Standards (Food Packaging), HACCP Awareness
- 2014, Ergonomics & Safety, Effective Environmental, Health & Safety Committee, Hazard Identification, Risk Assessment & Risk Control (HIRARC)
- 2013, AIB International Food Packaging Standards, Root Cause Analysis
- 2008, Positive Work Attitude
- 2007, ISO 14001:2004 Internal Auditor Training, Basic Firefighting and Emergency Response
- 2006, ISO 14001:2004 Internal Auditor Training, Introduction & Awareness to ISO 14001:2004, Training Need Analysis
- 2005, ISO 9001:2000: Introduction and Awareness, Occupational Safety and Health
- 2004, Advanced Problem-solving Process
- 2001, Emergency Response Plan and Preparedness
- 1999, Effective Supervisory Skills
- 1998, SMCT P 1 Practical Pneumatics (I), SMCT P 1 Practical Pneumatics (II)
- 1995, Spoken Japanese 1
- 1991, First Responder Training, (ERT) (I)
- 1990, First Responder Training, (ERT) (II)
Languages
English
First Language
Tamil
Intermediate (B1)
B1
Japanese
Intermediate (B1)
B1
Malay
Intermediate (B1)
B1
Timeline
MANUFACTURING MANAGER
BCS INTERGRATION SOLUTIONS SDN BHD-DAIFUKU OCEANIA
01.2021 - Current
Operations and Marketing Manager
MBf Printing Industry Sdn Bhd
01.2017 - Current
Assistant Manager Production
MBf Printing Industry Sdn Bhd
01.2011 - 12.2017
Production Planner
Georg Jordan (MALAYSIA) Sdn Bhd
01.2010 - 12.2010
Assistant Production Engineer cum Process Controller for Glass Fibre Plant
NIPPON ELECTRIC GLASS (MALAYSIA) SDN BHD
01.2001 - 12.2009
Junior Process Controller
NIPPON ELECTRIC GLASS (MALAYSIA) SDN BHD
01.1995 - 12.2001
Process Technician
NIPPON ELECTRIC GLASS (MALAYSIA) SDN BHD
01.1994 - 12.1994
Bachelor Degree of Science - Mechanical Engineering
University of Rockhampton
Executive Diploma - Double Major in Engineering & Business Management
Universiti Teknologi Malaysia