Summary
Overview
Work History
Education
Skills
Accomplishments
Certification
Affiliations
Projects
Timeline
Generic

Manoj Kumar Karri

Glen Allen,VA

Summary

As a senior operations manager at Productiv, Inc (TPL), successfully managed and overseen 10+ projects over 7.5 years. Trained and developed multiple managers and associates, contributing to their professional growth and the organization's success. Currently leading a project for the "Altria Group," focusing on maximizing process and workforce productivity. Implemented cost-reductive strategies, improving efficiency, inventory management, and quality control. Emphasizing leadership and training as integral components of management approach, integrate PMP concepts into workflows while leveraging techniques from lean, six sigma, and continuous improvement methodologies to enhance efficiency and minimize downtime. Proficient in data analysis and KPIs to support decision-making processes and manage budgets, driving the organization's mission forward.

Overview

8
8
years of professional experience
4
4
Certification

Work History

Senior Operations Manager

Productiv,inc
04.2017 - Current
    • Designed and implemented continuous improvement strategies leveraging KANBAN, Agile approaches, and Lean principles to align with organizational objectives and operational excellence.
    • Pioneered the implementation of Lean practices, automation trends, and Six Sigma approaches to enhance productivity and minimize waste.
    • Applied the 80-20 Rule (Pareto Principle) to prioritize high-impact areas, focusing on the 20% of processes driving 80% of operational outcomes, resulting in significant efficiency gains.
    • Developed and optimized workflows using FIFO methodologies, Kanban systems, and SOP adherence to ensure seamless operations in manufacturing and supply chain environments.
    • Integrated advanced systems such as SAP and Transportation Management Systems (TMS) for better visibility, control, and efficiency in logistics and operations.
    • Led, mentored, and trained managers and assistant managers across production, warehouse, and logistics functions to instill a culture of continuous improvement and accountability.
    • Created and delivered training programs on 6S, SOP compliance, and advanced tools to boost team proficiency and operational standards.
    • Guided team members in adopting and applying CAR (Corrective Action Requests) to resolve issues efficiently and prevent recurrence.
    • Managed projects to optimize fulfillment, procurement, and replenishment, ensuring compliance with safety, quality, and cost parameters.
    • Directed operations involving pick-pack processes, improving accuracy and speed while minimizing errors and costs.
    • Developed and implemented effective production and replenishment forecasting techniques using historical data to meet demand fluctuations and minimize downtime.
    • Created and deployed Power BI and Excel templates for coworkers to enhance reporting, forecasting, and efficiency in inventory and production workflows.
    • Leveraged data insights and Pareto analysis to identify key trends, measure performance, and guide strategic decision-making in production and logistics.
    • Collaborated with cross-functional teams and senior leaders to secure buy-in for continuous improvement initiatives and drive organizational change.
    • Ensured adherence to industry standards, regulations, and best practices in all processes, including GMP and GDP.
    • Managed resources effectively, ensuring optimal allocation of materials, labor, and equipment to meet production targets while controlling costs.
    • Developed budgets and approved expenditures for materials, ensuring alignment with organizational financial objectives.
    • Applied advanced methodologies like the 5 Whys, Fishbone Diagram, DMAIC, FTA, and Pareto analysis to troubleshoot issues and implement corrective actions.
    • Proactively identified and mitigated operational risks, ensuring minimal disruption to processes and maintaining compliance with standards.

Foundation Designer

Strand System Engineering
10.2016 - 04.2017
  • Managed multiple design projects concurrently, ensuring on-time delivery and high-quality results.
  • Developed innovative design concepts to enhance brand recognition and drive customer engagement.
  • Designed slab-on-grade post-tension foundations for various projects and authored SOPs and GDPs for training new team members.
  • Conducted in-depth analysis of project scopes, developed detailed process flows with timelines, and efficiently allocated tasks among team members.
  • Implemented and optimized workflows using FIFO methodologies and Kanban systems, streamlining operations for increased efficiency.
  • Monitored and tracked project activities using Power BI and Salesforce, ensuring visibility and accountability.
  • Maintained iterative communication with clients, providing regular project updates and incorporating feedback through change requests to meet expectations.
  • Produced high-quality mockups for client approval during the iterative design process, saving time on revisions later down the line.
  • Worked with architects, engineers and customers to efficiently resolve planning and construction issues.
  • Facilitated smooth transitions between project phases with thorough documentation of revisions and updates to drawings.
  • Developed prototypes for testing and presentation purposes.

AutoCAD Draftsman

Achanta Aceengineer India Pvt ltd
08.2013 - 06.2014
    • Draw Industrial machine parts representing them in 3D models using CATIA
    • Draw interior elevations, millwork elevations and sections and ceiling sections of hotel public areas
    • Streamlined drafting processes, resulting in increased efficiency and improved drawing quality.
    • Optimized workflow within the department by regularly maintaining CAD equipment, software, and related tools.
    • Collaborated with design and engineering staffs to solve AutoCAD and CATIA related issues.
    • Used computer-aided design software to prepare blueprints and schematics.
    • Improved communication between departments through clear and concise AutoCAD documentation of project details.
    • Worked with architects, engineers and customers to efficiently resolve planning and construction issues.
    • Facilitated smooth transitions between project phases with thorough documentation of revisions and updates to drawings.
    • Reduced errors on project designs by thoroughly checking dimensions, materials, and specifications before submission.
    • Aided in identifying potential design issues through meticulous attention to detail during the drafting process.
    • Ensured compliance with industry standards by consistently adhering to established drafting guidelines and protocols.
    • Enhanced design accuracy by diligently reviewing and updating AutoCAD drawings for various projects.

Intern/ CAD Designer

Pricol Technologies Ltd
09.2012 - 03.2013
  • Designed the motor gears and learned plotting machine design
  • Plotted parts of engineering drawings using AutoCAD
  • Maintained assemblies, detail drawing using CAD and CATIA software
  • Creating new designs for enclosures for new products and re-designing some existing products
  • Inspected the previous designs and made modifications to reach the client requirement
  • Maintained yearly ISO audit, internal audits, and training of internal auditors
  • Supported staff members in their daily tasks, reducing workload burden and allowing for increased focus on higher-priority assignments.
  • Developed organizational skills through managing multiple tasks simultaneously while adhering to strict deadlines.
  • Utilized strong communication abilities during presentations which led to increased understanding among colleagues regarding project goals and objectives.

Education

Masters - Industrial Engineering

Lamar University
Beaumont, TX
01.2015

Bachelor - Mechanical Engineering

Pondicherry University
India
01.2013

Skills

  • Lean and six sigma
  • Project Management(PMP)
  • TQM
  • Root cause analysis(RCA)
  • Continuous Improvement(KAIZEN)
  • Operation and research
  • Statistics Analytics
  • Data Analysis
  • Production and inventory control
  • Power Queries and SQL
  • SAP and ERP systems
  • Power BI and Excel
  • CAD

Accomplishments


  • Achieved and maintained 100% inventory accuracy over four years through tailored process improvements.
  • Developed templates and tools that streamlined workflows, improved accuracy, and enhanced efficiency across production and logistics teams.
  • Successfully implemented KANBAN systems to improve resource allocation, reduce inventory holding costs, and accelerate production cycles.
  • Increased operational efficiency by integrating Agile approaches, the 80-20 Rule, and Six Sigma methodologies, fostering a culture of continuous improvement.
  • Played a critical role in the strategic planning and execution of industrialization projects, ensuring smooth and successful program launches.
  • Created more than 50 different excel templates and still actively used in the enterprise on daily basis.
  • Maintained excellent customer relationship management (CRM) with all stakeholders I have collaborated with to date.

Certification

  • Project Management professional(PMP)
  • Six Sigma Green Belt
  • CATIA (v5 R21), CAD Pro Technologies
  • Pro-E, IGIAT (Indo German Institute of Advance Technology)
  • Auto CAD, CAD Pro Technologies



Affiliations

  • IIE (Institute of Industrial Engineers)
  • ASME (American Society of Mechanical Engineers)
  • SAE (Society of Automotive Engineers)
  • SAVE (Society of American Value Engineers)

Projects

Improvement of Mechanical Properties of Aluminum Alloy, To improve the mechanical properties of Aluminum Alloy (AA6061) by using friction stirring process., Studied the microstructure and microhardness of the aluminum alloy., Improved the grain size and hardness by using friction stirring process., Studied the mechanical properties of the material., Developed a process to improve the strength of the material at low cost. Evaporative Cooling System in Reheating, Vizag Steel Plant, Vizag, India, To study how the temperature of bloom beds are maintained constant in the furnace., Studied how the bloom is handled in the furnace., Studied how the bloom holders are maintained at a constant temperature inside the furnace., Developed safety levels in the cooling system of the furnace. Brain-computer interface robotic arm, To improve the robotic arm controlled by brain stimulation., Conducted analysis on a group of people and proposed an idea using brain-computer interface., Designed a prototype of the robotic arm. Simulation on Bank of America, To provide good customer service., Conducted Time-study to collect required data., Simulated the bank with Rockwell Arena using the collected data., Conducted value analysis of adding an extra employee.

Timeline

Senior Operations Manager

Productiv,inc
04.2017 - Current

Foundation Designer

Strand System Engineering
10.2016 - 04.2017

AutoCAD Draftsman

Achanta Aceengineer India Pvt ltd
08.2013 - 06.2014

Intern/ CAD Designer

Pricol Technologies Ltd
09.2012 - 03.2013

Masters - Industrial Engineering

Lamar University

Bachelor - Mechanical Engineering

Pondicherry University

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Manoj Kumar Karri