Manoj Joy
kilkenny
Summary
Accomplished Senior Production Manager with extensive experience in manufacturing management, industrial engineering, and process optimisation in the textile industry. Demonstrates expertise in lean manufacturing principles, quality assurance, and cost control strategies, achieving significant efficiency improvements and waste reduction across diverse production environments. Proven ability to lead cross-functional teams, implement innovative solutions, and foster a culture of continuous improvement. Adept at strategic planning, inventory management, and supplier negotiations to enhance operational performance while maintaining high-quality standards. Career highlights include a 20% increase in operational efficiency through lean practices and a 30% reduction in workplace accidents via enhanced safety protocols. Committed to driving excellence in production processes while aligning with organisational goals for sustained growth.
Overview
19
19
years of professional experience
1
1
Certification
Work History
Senior Production Manager
RK FACTORY FOR SUITS AND UNIFORMS
Doha
04.2022 - 01.2025
- Managed daily operations in production facility, optimising workflow and enhancing efficiency.
- Developed and maintained production schedules, ensuring timely delivery of products to clients.
- Resolved production issues swiftly, minimising impact on delivery timelines and customer satisfaction.
- Coordinated with multiple departments to streamline production processes, reducing downtime and costs.
- Implemented rigorous quality control measures, significantly reducing product defects and customer complaints.
- Developed and implemented production strategies and closely monitored results
- Oversaw inventory management, implementing systems to minimise stock levels whilst meeting production needs.
- Managed staff hiring, training and performance goals.
- Supervised a team of 200+ staff, providing training and development to foster a skilled workforce.
- Trained staff in Good Manufacturing Practices (GMP)s to drive consistently high standards.
- Facilitated communication between upper management and production floor, ensuring alignment with company objectives..
- Reduced workplace incidents by implementing occupational health and safety requirements.
- Planned project labour, expenses and timeframes to continuously achieve output and quality targets.
- Implemented lean manufacturing principles, minimising downtime and maximising resource utilisation.
- Tracked outgoing orders, identifying late deliveries and planning improvement action.
- Minimised costs by adjusting processes, managing budgets and controlling expenses.
- Collaborated with the R and D department to introduce new products, driving innovation and market competitiveness.
- Conducted performance evaluations, identifying areas for improvement and rewarding high achievers.
- Directed plant maintenance, operating schedule and supply management to minimise downtime.
- Developed and maintained robust supplier relationships, securing high-quality materials at competitive prices.
- Collaborated with marketing and sales teams to align production capabilities with market demands.
- Oversaw the implementation of new manufacturing technologies, improving product quality and production speed.
- Managed budget allocation for production departments, optimising resources to achieve financial targets.
- Directed workforce training programmes, increasing team productivity and reducing error rates by 20%.
IE Manager(5+years )+Production Manager(3 Years)
ALSIDDIQI HOLDING -INCH FACTORY(ALMOTAHAJIBA,DARY,AL SHAL)
Doha
02.2013 - 11.2021
- Oversaw daily operations within production environment, streamlining processes to boost productivity
- Developed systems and procedures to optimize workflow efficiency.
- Oversaw production department budget, achieving effective expense management.
- Assessed employee performance, recognizing excellence and identifying improvement needs.
- Planned and reviewed production line activities to adhere to schedules.
- Ensured on-time shipment fulfillment according to established timelines.
- Established quality control measures that elevated product standards.
- Collaborated with R&D to refine process flow prior to mass production.
- Implemented lean manufacturing principles, minimizing downtime and maximizing resource utilization.
- Designed optimized layouts for facilities to enhance operational efficiency.
- Analyzed workforce utilization metrics to improve overall productivity.
- Conducted training sessions to strengthen operator skills and competencies.
- Conducted machinery and asset valuations to support capital expenditure decisions.
- Optimized production workflows through effective line balancing techniques.
- Assessed operator efficiency and productivity to identify improvement opportunities.
- Enhanced operational procedures to maximize efficiency and minimize waste.
- Performed thorough analyses of work processes for continuous improvement.
- Facilitated open communication among operators to foster collaboration and feedback.
- Reviewed operational bulletins, trim consumption reports, and capacity studies for accuracy.
Industrial Engineer Manager
SHAHI EXPORTS
Bangalore
12.2010 - 11.2012
- Streamlined operations by implementing Traffic Light System for improved efficiency.
- Integrated Lean Production System, resulting in higher productivity levels.
- Kanban system successfully implemented to enhance workflow efficiency.
- Utilized GSD to establish standardized operational methods.
- Designed line concepts that significantly shortened changeover time.
- Enhanced operational efficiency through optimized machinery resource allocation.
- Managed comprehensive production operations to streamline workflow.
- Facilitated effective planning by contributing to pre-production meeting agendas.
- Ensured readiness by participating in pre-production activities.
- Minimized expenses through diligent management of garment costing processes.
- Reviewed operational bulletins and capacity study reports to inform strategic decisions.
- Monitored trims to optimize material consumption across production processes.
- Developed strategies to reduce factory expenditures effectively.
- Generated comprehensive assessment reports for operators to enhance performance.
- Determined production targets for cutting, stitching, and finishing departments using SAM values.
- Assessed staffing requirements based on style delivery schedules.
- Created style analysis reports to inform upcoming design initiatives.
- Implemented new folder systems and machinery to improve operational efficiency.
Team Leader for Industrial Engineers
GOKALDAS EXPORTS PVT LTD(HEAD OFFICE)
Bangalore
09.2009 - 11.2010
- Managed four factories, producing detailed project reports for submission.
- Developed SAM estimation and cost study reports to inform budgeting.
- Oversaw capacity booking to optimize resource allocation.
- Planned factory efficiency to enhance operational performance.
- Calculated lead time for deliveries to ensure timely fulfillment.
- Guided factory production team to achieve estimated SAM through effective project management.
- Designed and implemented line layouts to reduce changeover times and enhance efficiency.
- Assigned projects and directed factory industrial engineers to ensure successful execution.
- Executed machinery planning to optimize production capabilities across facilities.
- Allocated styles to factories for improved resource utilization and workflow efficiency.
- Implemented modular line concepts in factories to streamline operations and increase flexibility.
- Introduced new folders and machines, enhancing production processes and organization.
Senior Industrial Engineer
GOKALDAS EXPORTS PVT LTD - NEW GENARATION APPARELS-II
Bangalore
10.2007 - 08.2009
- Implemented Lean production system to enhance quality within textile industry.
- Conducted root cause analysis to identify deviation factors.
- Reduced lead time across all processes in garment manufacturing.
- Eliminated waste through effective application of Lean principles.
- Prepared operational bulletins, trims consumption reports, and capacity study reports.
- Designed workflows to minimize changeover time and improve efficiency.
- Implemented one-piece movement to enhance operational efficiency.
- Executed Point-Kaizen initiatives in critical operations for continuous improvement.
- Recovered all amendments during sample stage to ensure quality compliance.
- Monitored hourly production and resolved bottlenecks to maintain workflow.
- Managed setup of new 600 m/c multi-product manufacturing unit in Bangalore.
- Conducted training programs for local laborers on manufacturing processes and techniques.
- Executed machine installation and trial runs in new factory setting.
- Applied knowledge of factory planning, machine ratios, and operational benchmarks.
- Conducted cost reduction studies and monitored thread consumption reports.
- Developed operator grading systems to enhance efficiency during style transitions.
- Implemented strategies for minimizing changeovers between styles.
- Designed comprehensive production plans using balancing matrices and flexibility metrics.
- Managed production lines for international brands including MEXX, PUMA, ADDIDAS, A&F, OLLILY, GAP, and NICKY.
Industrial Engineer
GOKALDAS EXPORTS PVT LTD - ATLANTIC APPARELS-II
Bangalore
08.2006 - 09.2007
- Developed operation sequences and layouts to enhance efficiency.
- Conducted time studies and set targets using PRO-SMV software.
- Prepared thread consumption reports to track material usage.
- Compiled style analysis reports for production assessment.
- Recruited manpower and managed machine installation processes.
- Established performance targets for optimized productivity.
- Achieved daily OCT reduction until peak production was reached.
- Conducted operator capacity studies to identify efficiency improvements.
- Updated skill matrix by style to enhance workforce capabilities.
- Balanced manpower allocation to optimize productivity across departments.
- Monitored material utilization to minimize waste and reduce costs.
- Established a new 150 m/c shirt manufacturing unit, designing layouts for all departments.
- Designed work aids to boost productivity and trained staff on SPC systems for quality assurance.
- Collaborated with woven shirt buyers including MEXX and SPYKAR.
Management Trainee –Junior Industrial Engineer
GOKALDAS EXPORTS PVT LTD - TRIANGLE-II
Bangalore
12.2005 - 06.2006
- Responsible for Time study and target setting using PRO-SMV Software(SAME AS GSD).
- Responsible for the production and quality control activities of one line consisting of 60 machines.
Education
Diploma (3 Years) - Computer Engineering
GOVT POLYTECHNIC
KERALA03-2004
PRE UNIVERSITY COLLEGE (2 Years) - Science
MES COLLEGE
KERALA04-2001
High School -
ST. Xavier's Higher Secondary School
KERALA04-1999
Skills
- Positive attitude
- Creative thinking
- Time management
- Decision making
- Production planning
- Manufacturing leadership
- Customer relationship management
- 5S methodology
- Workforce motivation
- Performance monitoring
- Decision-making efficiency
- Production forecasting
- Inventory control
- Budgeting and cost control
- Quality assurance techniques
- Supply chain management
Languages
Malayalam
First Language
English
Advanced (C1)
C1
Hindi
Proficient (C2)
C2
Tamil
Advanced (C1)
C1
Workplace training programs
- TLS TRAINING : WALMART BUYER.
- GSD TRAINING : SHAHI EXPORTS.
- LEAN PRODUCTION SYSTEM : GOKALDAS EXPORTS.
Certification
- PRO-SMV TRAINING : GOKALDAS EXPORTS.
Accomplishments
- My first employer, Gokaldas Exports PVT LTD, hired me as a junior industrial engineer to start my career; I eventually became an industrial engineer, then a senior industrial engineer, and a team leader as a result of my diligence
- I was employed as an industrial engineer by Al Siddiqi Holding. After five years of hard effort, I was promoted to production manager for the following three years
References
References available upon request.
Timeline
Senior Production Manager
RK FACTORY FOR SUITS AND UNIFORMS
04.2022 - 01.2025
IE Manager(5+years )+Production Manager(3 Years)
ALSIDDIQI HOLDING -INCH FACTORY(ALMOTAHAJIBA,DARY,AL SHAL)
02.2013 - 11.2021
Industrial Engineer Manager
SHAHI EXPORTS
12.2010 - 11.2012
Team Leader for Industrial Engineers
GOKALDAS EXPORTS PVT LTD(HEAD OFFICE)
09.2009 - 11.2010
Senior Industrial Engineer
GOKALDAS EXPORTS PVT LTD - NEW GENARATION APPARELS-II
10.2007 - 08.2009
Industrial Engineer
GOKALDAS EXPORTS PVT LTD - ATLANTIC APPARELS-II
08.2006 - 09.2007
Management Trainee –Junior Industrial Engineer
GOKALDAS EXPORTS PVT LTD - TRIANGLE-II
12.2005 - 06.2006
Diploma (3 Years) - Computer Engineering
GOVT POLYTECHNIC
PRE UNIVERSITY COLLEGE (2 Years) - Science
MES COLLEGE
High School -
ST. Xavier's Higher Secondary School
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