Saranya Balaji Email and Phone Number

Leadership and Operations Management: Managed key customers in Mobile Phones, Consumer Electronics, Telecom, and Automotive (EV) Power Electronics, overseeing the entire product life cycle process from NPI to EOL. Led 30 manufacturing lines covering SMT, Test and assembly, MI, THT, Wave soldering, Selective soldering, Conformal coating, Potting, ICT FCT, and packing. Ensured daily production plan adherence, achieving target output, implementing best practices, and managing customer audits while meeting production and quality standards. Monitored KPIs such as Productivity, Yield, OEE, Operator Efficiency, Scrap, Stock Accuracy, Safety, Line Balancing, 5’s, and Work order management.Team Management and Development: Executed DL Skill Development and designed DL's skill set framework (Level 1, 2, 3 & 4). Ensured team multiskilling and evaluated the skill matrix for maximizing productivity.Process Improvement and Quality Control: Enhanced training for new operators on the shop floor, emphasizing safety, product knowledge, 5s, and ESD. Analyzed daily Rejection and Rework Problems using why-why analysis. Prepared work instructions in collaboration with process engineers. Led the installation and ramp-up of new SMT & Final Assembly lines for Tejas and ABC Customer. Conducted new operator training and updated the skill matrix. Contributed to Production Operations aiming to manufacture 1 Billion Mobile Phones. Monitored and managed the entire production process, proactively preventing and swiftly resolving any instances of downtime. Implemented strategies to significantly reduce scrap, enhancing overall production efficiency and resource utilization. Ensured the smooth start of production by confirming material and manpower readiness and availability. Addressed daily issues, created awareness among associates, and communicated technical changes, ensuring implementation.

 Spearhead resource planning, including recruitment, training, and stage allocation for operators. Evaluate operator performance through On-the-Job Training (OJT) programs. Lead efforts to achieve Key Performance Indicators (KPIs) such as Units Per Hour (UPH), Yield, Operator Efficiency, Scrap reduction, Safety compliance, and effective Work Order management. Ensure seamless operation by managing 5's practices for a clean and organized workplace. Enhance training programs for new operators on the shop floor, covering aspects of working safety, product knowledge, 5S, and Electrostatic Discharge (ESD) precautions. Ensure the realization of agreed-upon production capacities, yields, cycle times, and quality standards. Conduct detailed analysis of daily rejection and rework issues using methodologies such as the "why-why analysis" to identify root causes. Drive continuous improvement initiatives based on analysis outcomes. Guarantee the availability of materials for the production plan, ensuring uninterrupted workflow. Proactively work towards and achieve production targets in alignment with the overall production plan

 Lead the production operations of the Mobile Phone Section, overseeing a dedicated team of associates. Ensure a smooth start of production by verifying the readiness and availability of materials and manpower.Order Fulfillment and KANBAN Implementation: Take responsibility for meeting order fulfillment targets according to the daily plan, utilizing KANBAN principles to enhance efficiency.Technical Support and Troubleshooting: Provide essential technical support to associates, understanding their challenges and assisting them in achieving agreed-upon production targets. Offer troubleshooting expertise for process defects, ensuring quick response actions to maintain a seamless production flow. Escalate issues to Process leaders if necessary.Team Empowerment and Development: Empower and develop the team to elevate their skills and performance to the next level. Facilitate line setups and product changeovers with minimal downtime, optimizing operational efficiency.Training and Mentorship: Monitor and provide training for junior and new staff, fostering a culture of continuous learning and development. Analyze and address issues related to both man and machine, implementing permanent solutions.Factory-Level Skill Matrix Project Coordinator | Year 2009 Spearheaded the implementation of the Mentor-Mentee training concept, significantly improving the skills of new, unskilled operators to meet peak production requirements.Core Team Member for Lean Assembly of Mobile Phones | Year 2010 Contributed as a core team member to implement Lean Assembly Cells for Smartphones, reducing changeover time from 20 minutes to an efficient 5 minutes.Shop Floor Optimization through Value Stream Mapping | 2011 Reclaimed 320 square meters of shop floor space by establishing a unidirectional flow from raw material storage to the finished goods shipping dock, following Value Stream Mapping (VSM) principles and eliminating identified wastes.

 Strategically manage material and workforce resources to meet production requirements, optimizing efficiency and minimizing resource waste. Vigilantly monitor and manage the entire course of production, ensuring adherence to quality standards, timelines, and performance metrics. Proactively identify potential causes of downtime and implement preventive measures to mitigate risks. Swiftly and effectively resolve downtime issues in the case of unavoidable occurrences, minimizing disruptions to production schedules. Implement initiatives and best practices aimed at reducing scrap, optimizing processes, and enhancing overall product quality. Continuously analyze and refine production processes to minimize waste and improve overall efficiency.