Seager Karuppannan
Bukit Mertajam
Summary
Experienced Senior Production Manager with a proven track record of optimizing manufacturing processes, increasing efficiency, and reducing cost. Leverage expertise in team leadership and continuous improvement to drive operational excellence and exceed organization goals.
Demonstrated ability to: - Effectively lead, coach and develop a large work team to accomplish operational objectives - Identify, diagnose and resolve operational, manufacturing and maintenance problems within deadlines - Plan work flow, manage multiple priorities and meet daily production targets while consistently reducing downtime - Develop new procedures and processes to improve production accuracy - Set up health and safety audit procedures and improve safety efficiencies - Competently utilize Lean Manufacturing, Six Sigma, SPC and related process improvement techniques to ensure the most cost-effective manufacturing process - Establish and maintain acceptable quality levels for all assigned products - Interpret and develop reports including standard operating procedures - Efficiently set and control operational budgets - Monitor business unit budget, financial performance, scrap, cost, physical inventory count, labor efficiency, work order aging.
Overview
24
24
years of professional experience
1
1
Certification
Work History
Senior Production Manager - Production and Kitting
Sanmina SCI Technology Sdn. Bhd.
10.2019 - Current
- Led a team of 580 production staff in a high volume manufacturing environment, ensuring adherence to production schedule and quality standards
- Spearheaded cross-functional initiatives to streamline workflows, minimize downtime, and improve overall equipment effectiveness (OEE)
- Collaborated with engineering teams to introduce new product and processes from concept through to production, ensuring smooth transitions and timely launches
- Managed inventory levels to meet production demand while minimizing excess inventory and reducing carrying cost
- Developed and implemented training programs to enhance employees skills.
Production Manager - Medical Division
Sanmina SCI Technology Sdn. Bhd.
12.2014 - 09.2019
- Managing operations for Medical Division
- Develop and execute production schedules based on business demands
- Maximize effectiveness of production team, equipment and materials to produce multiline products within planned schedules while reducing costs
- To ensure drive Business Excellence Program and Kaizen activities and continuous improvement initiatives in the plant
- Set Goals and KPI for each Business Unit
- To ensure follow customer requirement on the product sensitivity
- Managing operations with FDA, ISO13485 requirement (Medical) and IPC-A-610
- Successfully completed Medical FDA Audit (October 2016)
- Control inventory and raw material handling
- Lead all Production inventory management activities including coordinating the entire department yearly cycle-count activities
- Facilitate quality improvement activities in terms of system and processes
- Ensure Good manufacturing practices (5'S & Floor Discipline).
Production Assistant Manager, Cisco Operation (Production & Kitting)
Flextronics Technology (Penang) Sdn. Bhd.
01.2011 - 11.2014
- Develop and execute production schedules based on business demands
- Maximize effectiveness of production team, equipment and materials to produce multi-line products within planned schedules while reducing costs
- Manage high volume manufacturing of more than 100 products per month
- Attain a sustained improvement of 5% in productivity over the last year
- Develop and track cost improvement projects to reduce production costs by 5%
- Lead, develop and evaluate production staff of 240 members
- Manage activities related to strategic purchasing to minimize operating expenses
- Control inventory and raw material handling
- Cost, plan and control all indirect materials
- Design, implement and audit quality control processes
- Assist with new cost quotes and price quotations for products
- Driving production for shorter cycle time and OTD performance
- Reduced material preparation lead time by 12 working hours thru centralization of Kitting and MH operation inside the same place
- This integration also resulted cost saving of estimated US$200,000 per annum due to optimization of manpower and reduction of transportation cost
- Managed a team of 240 directs labor (Material Handlers) and 15 Indirect staffs (Admin Assistants, Supervisors, Material Coordinators)
- Lead all Production inventory management activities including coordinating the entire Department quarterly cycle-count activities in 9 different functional areas within Plant 2 operation
- Represent Operation Team in material system development team which successfully implemented a new ERP system Baan to replace Infimacs II application
- The entire development and implementation of Baan system in Flextronics Plant 2 took about 2.5 years to complete
- Established a sub-team to work as a catalyst between the system developer and users to ensure smooth transition during migration of ERP system
- Operation focal person in dealing with Finance on key production financial indicators such as operating supplies expenditure, operation attrition, yearly audit and other matters pertaining material expenditures whichever related to the operation
- Works very closely with Material Planning, Production Planning, Procurement and Warehouse to supply material kits to the production floor on timely manner and prevent any downtime in SMT due to material issues
- Also deals with Engineering and Program Management in preparing special material kits for NPI, ECO or Qual builds
- Also directly involves with CSCM in supporting inter-site shipments and others E&O related matters.
Production Superintendent/Senior Superintendent, Cisco Operation
Flextronics Technology (Penang) Sdn. Bhd.
09.2007 - 12.2010
- Lead entire SMT and Backend for Cisco products and need to plan on functional test, capacity, test configuration and model configuration
- Plan the capacity based on customer demand and fulfill the entire requirement with 4M resources
- Achieve results without compromising on company's ethics, integrity, behaviors and core values
- Prioritize, focusing efforts on those issues that affect results the most
- Identify issues or potential problems and mobilize the right people in the organization to address them
- Ensure that issues are solved to prevent reoccurrence
- Use variety of tools and techniques to solve problems and make decisions in order to minimize the risk while ensuring the maximum benefit and return
- Lead, coordinate and motivate a team of Supervisors and operators to ensure smooth production line processes and achieve optimum output, quality and cost of finished product
- Continuously driving develops and seeks for product quality, productivity and cost improvement
- Coordinate to resolve major problems encounter in the production and to allocate and ensure optimization of available resources such as materials, equipment, facilities, and personal to achieve objectives
- To ensure standards of quality, productivity, waste reduction, complete and on time delivery
- Facilitate quality improvement activities in terms of system and processes
- Ensure Good manufacturing practices (5'S & Floor Discipline)
- Build, develop and manage operations team capable of carrying out needed operations strategies and improving employee relations.
Senior Material Control Supervisor
Motorola Technology Sdn. Bhd.
08.2006 - 09.2007
- Headed a Material Handling group consists of 40 Material Handlers (direct labor)
- Our team major task is pulling materials kits from Warehouse and converts it into a complete feeder set ready to load into SMT machine at least 8 hours prior to the actual build plan
- Our team performed all materials documentation, transaction and logistics movement of the kits from Warehouse until SMT line (end to end material pulls system)
- We also responsible to manage balance materials return from SMT line after work order completed to be reconciled and re-process for next kit or return for safekeeping in the Warehouse
- Hired and trained initial staffs
- Conduct periodic training programs to improve their skills and potentials
- Fully responsible for staff retention program, performance review and career advancement
- Provided mentoring and direct to the management group in the execution of daily roles and responsibilities
- Spearheaded a diverse range of programs and projects leading to improved material control system especially within Production WIP in terms of work order aging reduction, scrap control and cycle-count improvement
- Tackled all employee working problems quickly and straight in reference to company employee's policies/procedures
- Ensure instructions, rules processes were communed to each operations employees.
Production Supervisor
Solectron Technology Sdn. Bhd.
07.2002 - 08.2006
- As a production executive, need to ensure SMT and Backend shiftily plan or outputs are achieved without fail
- The main objective will be to achieve company policy whereby to ensure total customer satisfaction through excellence in product and service quality
- Leading SMT and Backend for Brocade, Stratus and Teradyne account
- In charge for 2 SMT, 2 Backend line in achieving numbers
- Total manpower for SMT and Backend line will be 70 operators
- To be success in SMT line I have to plan according to 4M (Manpower, Machine, Material and method)
- The objective is to overseeing the smooth running of production line through executing on produce and provides products with service of highest quality to satisfy customer requirement on performance
- Production Executive role also including in assists for controlling production processes via executing documented specifications to ensure that the company's goals and achievement are met with adequately
- Lead and motivates a group of workers to achieve quality, productivity, cost reduction, low attrition and zero scrap
- The above responsibilities will be monitor with key performance indicators such as Hourly Output Tracker, Daily cost control log sheet and two hourly GYAT for healthy forums to review the production line performance
- An executive will authorities for appraisal performance, promotion, and confirmation and salary review recommendation for direct employers
- Beside that approval for overtime and annual leave application will be under executive responsibilities
- Ensure daily shipment and on time delivery achieved
- Assist Process Engineer on all NPI and QUAL builds
- Ensure weekly department indicator-labor efficiency, absenteeism
- Involve in Improvement Plan Team to reduce headcount plan, bone pile, process improvement.
Assistant Supervisor
ST Assembly Test Services (Ltd) Singapore
06.2000 - 06.2002
- Managing Backend processes after test
- Strategize line loading by product priorities and line focuses to meet weekly/quarterly revenue
- To meet 100% weekly volume by customers, demand while maintaining production indicators
- People management i.e
- Headcount Competency Skills planning & training, Equipment Allocation by Headcount (manning ration management)
- Drive towards ZERO Quality issues in Backend
- Apply and adapt Low Volume Manufacturing (LVM) Business Processes in supporting customers' requests based on factory's LVM cycle time
- Demonstrated leadership qualities in leading/forming the Manufacturing Team in Backend operations which includes re-align organizational objectives and goals by achieving positive revenue closure.
Education
Master in Business Administration - Supply Chain Management
UNITAR International University
12.2023
Bachelor in Business Administration - Finance
Northern University of Malaysia (UUM)
01.1999
Sijil Pelajaran Tinggi Malaysia (STPM) -
Sekolah Menengah Kebangsaan Kulim
01.1996
Sijil Pelajaran Malaysia (SPM) -
Sekolah Menengah Lunas
01.1993
Skills
- Production Planning and Scheduling
- Safety Compliance
- Lean Manufacturing Principles
- Team Leadership and Development
- Continuous Improvement
- Inventory Management
- Cross-Functional Collaboration
Certification
- Lean Six Sigma Green Belt
- ISO13485 - 2012 Process Based Internal Auditing
- MDSAP - Awareness for Working Group
- Internal Auditing
- ISO14971 - Medical Device Risk Contract Manufacturer
Languages
Bahasa Malaysia
English
Professional Development
- Attended various management and operation training including Supervisory Development Training, Emotional Intelligent (EQ), Effective Communications and Effective Negotiation Skills conducted by professional trainers.
- Completed Solectron MRP (Infimacs II) overview training conducted to all key Operation, Engineering and Program Management personnel as part of leadership development skills. This training was conducted by an internal MRP expert from Finance and IT.
- Co-developed End User Training modules of Baan System to support Flextronics ERP migration from Infimacs II to Baan IV in 2010. Conducted major training to the end users especially during on the job training to accelerate their familiarization into the new system.
Personal Information
- Salary: RM18,000
- Expected Salary: RM25,000 (Negotiable)
Carallowance
RM1,000
References
- Mr. Paul Louise, Senior Supply Chain Manager, Cepheid, 012-5603369
- Mr. Ravi Subramaniam, Sr.Warehouse/Logistic Manager, Micron Memory Sdn Bhd, 016-4671775
Timeline
Senior Production Manager - Production and Kitting
Sanmina SCI Technology Sdn. Bhd.
10.2019 - Current
Production Manager - Medical Division
Sanmina SCI Technology Sdn. Bhd.
12.2014 - 09.2019
Production Assistant Manager, Cisco Operation (Production & Kitting)
Flextronics Technology (Penang) Sdn. Bhd.
01.2011 - 11.2014
Production Superintendent/Senior Superintendent, Cisco Operation
Flextronics Technology (Penang) Sdn. Bhd.
09.2007 - 12.2010
Senior Material Control Supervisor
Motorola Technology Sdn. Bhd.
08.2006 - 09.2007
Production Supervisor
Solectron Technology Sdn. Bhd.
07.2002 - 08.2006
Assistant Supervisor
ST Assembly Test Services (Ltd) Singapore
06.2000 - 06.2002
Master in Business Administration - Supply Chain Management
UNITAR International University
Bachelor in Business Administration - Finance
Northern University of Malaysia (UUM)
Sijil Pelajaran Tinggi Malaysia (STPM) -
Sekolah Menengah Kebangsaan Kulim
Sijil Pelajaran Malaysia (SPM) -
Sekolah Menengah Lunas
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