Sudhakar Sivaraj

  • Selinsgrove PA

Director of Operations

Work History

Work History
Mar 2014 - Jul 2015

Director of Operations

Thermal Product Solutions, New Columbia, PA
  • $17M Revenue in Q2 2014, biggest Quarter in History of TPS
  • Balanced Operations for 100% growth in Gruenberg Product Line($5M to $10M) Expanded plant capacity through strategic outsourcing of cabinets, raw as possible and make vs buy initiatives
  • Implemented capacity planning tool to facilitate job scheduling, resource allocation and over time decisions
  • Balanced Operations to meet 30% average lead time reduction across all standard products
  • Implemented quick ship programs reducing lead time on select products from 20 days to 5 days
  • Created warranty ownership on rolling top ten trends related to operations Justified
  • 3 year ROI and replaced old punch machine with$ 500 K CO2 Laser
Jun 2012 - Feb 2014

Director of Engineering

SPX Thermal Product Solutions, New Columbia, PA
  • Key functions include Applications Engineering, Sustaining Engineering and New Product Development.
  • Balanced engineering organizational structure to create focus and maximize productivity.
  • Implemented Dashboard for tracking performance metrics and created ownership at the grass root level.
  • Implemented RFQ Life Cycle Report to track Quote Turnaround Times
  • Implemented SolidWorks EPDM system to securely store and index design data for fast retrieval & version control.
  • Led System Level Kaizen Events on 2 Key Product Lines
  • Managed 7 product launches, 2 Patents in 2013.
Nov 2011 - Jun 2012

Quality Manager

SPX Thermal Product Solutions, New Columbia, PA
  • Engaged supervisors in weekly 360 meetings, root cause analysis and problem solving.
  • Created a user friendly Web based Quality System by integrating 5 ineffective independent databases.
Feb 2010 - Nov 2011

Continuous Improvement Manager

SPX Thermal Product Solutions, New Columbia, PA
  • Developed a Real Time Performance Monitoring System for tracking timelines and margins on custom products.
  • Led a product rationalization team, rationalized 120 models to 80 and aligned pricing with the competition resulting in$ 500K YOY margin impact.
  • Supported purchasing to improve the data integrity in our business system through lead time policy, lead time maintenance, min max policy and date accuracy.
  • Created a Web based RFQ System for quoting custom products, the dashboard provides real time visibility on the status of all RFQ's and Quotes.
  • Reduced Quote Lead Times from 4 days to 4 minutes on select standard products through Instant Quote process.
  • Revitalized Goal Deployment process and tailored it for our business. Implemented pull systems in Fab Shop with a CAP of 4 orders in between each process.
  • Trained over 150 people on Lean Foundations(5S, 8 Wastes) & Tools like Value Stream Mapping, Kanbans, Load Leveling, Line balancing, set up reduction etc.
  • Directed a cross functional E&O team and disposed $ 1M inventory in 2010.
Apr 2008 - Feb 2010

Continuous Improvement Manager

SPX Kayex, Rochester, NY
  • Transformed operations to meet 110% increase in sales growth for fiscal year 2008 ($80M Revenue).
  • Increased production capacity of the facility by 140% by restructuring the plant layout.
  • Established Modular Build system, ECR system & Quality system.
  • Improved WIP turns by 159% by implementing pull systems and modular kitting process, the batting order production control process sequenced the orders and aligned all support functions.
  • Streamlined spare parts shipment process for a 24 hour turnaround time, created reports to manage orders and track on time delivery.
  • Introduced Inventory Forecasting Process by integrating OTTO software with AS 400 system, the software allowed us to analyze “what-if” scenarios.
Aug 2006 - Apr 2008

Continuous Improvement Engineer

SPX Thermal Product Solutions, New Columbia, PA
  • Improved plant wide production control resulting in on-time delivery improvement from 67% to 98% over a period of 2 years.
  • Achieved 40% productivity improvements by synchronizing support functions, enhancing visual production control, balancing the assembly lines and regulating the work flow.
  • Reduced lead times by 50% and achieved 200K YOY savings by consolidating electrical slide trays from 86 part numbers to 1.
Jan 2005 - May 2006

Research Assistant/lean Facilitator

University of Kentucky, Lexington, KY
  • Restructuring Plywood Manufacturing Operations Project for Columbia Forest Products, VA.
  • Internal Logistics and Conveyance Simplification Project & AGV Capacity Calculation between IP Install and IP Assembly Project for Toyota Motor Manufacturing, KY.
  • Facilitated lean training for Tyco Health Care, Yorktown Industries, Columbia Forest Products, Danville Community College, Boeing, Ingersoll Rand, Komatsu, Sara Lee etc.
Jun 2000 - Jun 2004

Production Manager

Essem International Company, Laemchabang, Thailand
  • Production Manager Responsible for managing the day to day operations which includes blank cutting, nickel plating, ultrasonic cleaning and tip manufacturing.
  • Increased the plant capacity by adding 10 cycles to existing 6 cycle plant. Improved throughput by 100% by modifying 6 single cycle machines into double cycle.
  • Reduced overall machine changeover and setup times by 50%.
  • Involved in Launching 30 new products which demands intricate tool designs and accurate machine setup.

Education

Education
2004 - 2006

M.Sc

University of Kentucky
1996 - 2000

B.Sc

Anna University

Certifications

Certifications
Sep 2009 - Jan 2010

SPX Lean Lead Facilitator Certification

MSOE
Aug 2004 - Jun 2006

Lean Systems / Six Sigma Certification

University of Kentucky

Training

  • SPX Innovation Training
  • Center for Creative Leadership (CCL) Advanced Leadership Training
  • Leadership Training at Pennsylvania College of Technology
  • Development Dimensions International (DDI) Certification