Zoran Cholakov

Supervised injection molding production, managing process engineers, technicians, team leaders, and operators, to optimize efficiency and ensure adherence to quality standards

• Innovated and implemented novel production process, elevating production adherence from 55% to impressive 85%
• Investigated and implemented ideas for quality improvement, increased productivity and cost reduction
• Played pivotal role as part of the validation team for the prestigious FlexPen project at Novo Nordisk, delivering substantial reductions in validation time and elevating validation success rates
• Managed documentation of and training on production procedures and work instructions
• Maintained and communicated daily productivity and shipment reports for all departments
• Verified that all process parameters were being documented and followed at all times
• Led daily morning meeting where production plan was determent together with all department
• Created and updated department work instructions and reports on regular basis.

Leading the BMW production area department with a team of 600+ subordinates across assembly lines Electrical testing and packing processes

• Devised and implemented a refined organizational structure within production area, delineating explicit goals and objectives to streamline operations
• Engineered and executed a revamped layout to enhance process and material flow, optimizing efficiency
• Applied 5S methodology meticulously across production lines and areas, fostering a culture of cleanliness, organization, and standardization
• Pioneered the introduction of comprehensive production reports, facilitating meticulous monitoring and analysis for informed decision-making
• Crafted and deployed an innovative bonus concept, integrating revised targets and introducing individual efficiency metrics to incentivize peak performance
• Implemented cutting-edge visualization management techniques, fostering cross-departmental alignment and accountability through daily result and target integration
• Led the rigorous project planning efforts for BMW G60, ensuring adherence to stringent deadlines and milestones
• Drove a remarkable increase in production efficiency for the BMW G70 project, elevating performance metrics from 56% in July to an impressive 92% by October.

Overall responsible for overseeing manufacturing operations and driving strategic development initiatives to ensure optimal performance and growth

• Designed and implemented comprehensive layout for the entire plant in compliance with HACCP standards, ensuring food safety and quality assurance
• Developed new organizational structure with clearly defined job responsibilities and introduced new working positions to enhance efficiency and accountability
• Established supply matrix to identify potential raw material suppliers locally and internationally, ensuring a robust and diversified supply chain
• Designed and implemented material storage and flow systems in the warehouse to streamline operations and minimize waste
• Prepared day-to-day production plans based on customer orders and available resources, ensuring timely delivery and efficient resource utilization
• Created 2022 Capex and Opex budget, as well as P&L analysis for the upcoming year, to support strategic decision-making and financial planning
• Formulated a new employment plan and provided direction for workforce development over the next five years, ensuring alignment with organizational goals and growth objectives
• Accountable for production output, product quality, and on-time shipping, maintaining focus on meeting customer expectations and satisfaction.

Production Supervisor with responsibilities encompassing oversight of the Final Assembly Department, Plastic Injection Molding Department, and Maintenance Department

• Developed comprehensive layout for the Production area, optimizing space utilization and workflow efficiency
• Played key role in the recruitment, interviewing, and selection processes for new staff, ensuring alignment with organizational goals and departmental needs
• Directly responsible for creating and implementing Work Instructions (WI) and procedures for the Final Assembly and Molding departments
• Led the development and execution of plans for fully automated molding production, leveraging robotics and conveyor belts to reduce operator count from 22 to 10 per shift
• Established daily reporting mechanisms, enabling the smooth flow of information and communication for all production activities
• Recognized as best in the WIK Group for 2020 for production Key Performance Indicators (KPIs) including Final Assembly efficiency, Machine utilization, On-Time Delivery (OTD), and customer complaints
• Provided leadership for the successful day-to-day operation of the facility, ensuring efficient and productive manufacturing process
• Responsible for conducting annual inventory audits for Final Assembly, Molding Department, and secondary operations
• Served as project leader for the Piccolo XS relocation project, overseeing tool transfer, new assembly line build-up, and relocation of the entire production to new facility
• Successfully planned relocation of Final Assembly line from Batam, Indonesia, ensuring seamless transition and minimal disruption to operations
• Spearheaded the implementation of new technical solutions to enhance reliability of functional testers, improving testing efficiency and accuracy.

Production Shift Leader, entrusted with overseeing more than 350 operators across 6 production line. Additionally served as Deputy Production Area Manager, providing leadership and support in managing day-to-day operations

• Ensured achievement of ramp-up plans and production targets, driving operational excellence and meeting organizational objectives
• Implemented improvements in technical and organizational processes within production department, enhancing efficiency and productivity
• Proactively identified and resolved any weak points or problems in the production flow, minimizing disruptions and optimizing output
• Monitored and ensured attainment of key performance indicators (KPIs) such as Efficiency, First Pass Quality (FPQ), Reject Rate (RW), external/internal PPM (Parts per Million), absenteeism, and fluctuation
• Successfully achieved production KPIs until End of Production (EOP) on BMW R60M project, demonstrating consistent performance and adherence to targets
• Contributed to continuous improvement initiatives for B9M project, focusing on enhancing efficiency, output, and product quality
• Reviewed all internal and external PPM metrics, implemented corrective measures, and worked towards achieving zero defects
• Led team on the first production line at KSMK following successful relocation of the BMW project from plant in Timisoara.