Management Consultant

Launched 1M sq.ft. latest tech. Amazon Robotics building in Hamilton, ON with over 5000 employees, 200+ managers, ship volume of 4 million units/wk., inventory of over 30 million units, variable cost budget of over $250 million, fixed cost of $80 million and generated revenue of over $4 billion. Set up the processes, onboarded and trained associates/managers to ramp the building on time and within budget successfully

Directly managed 5 senior managers, led a team of 80 managers and over 4000 employees. P&L responsibility of approx. $150 million, revenue of over $2.5 billion, and inventory management over 27 million SKU's. Key Accomplishments:

costs, splits cost, warehouse VCPU, relevant workforce pool and bylaw constraints.
• Launched YYZ7 in September 2019 and exceeded the volume plan by 10% within 12 weeks.
• Increased YOY ship capacity by 30% and reduced cost by 9%. Senior Operations Manager September 2017 – March 2020 Directly manage 4 Operations Managers and indirectly manage 20 area managers overseeing 1000+ employees. Key Accomplishments:
• YYZ7 achieved fastest ramp in CACF, processed 17% more volume to plan and saved 20k hours in 3 months.
• Improved performance to benchmark by 24% in productivity in Inbound value stream

Responsible for driving supply chain improvements in warehousing, Inventory management, transportation and customer service at 6 different warehouse locations with approx. ~1000 employees and $800M+ revenue. Collaborate with key supply chain leaders, procurement, 3PL and transportation to execute business transformation strategy. Assess financial budgets of different sites in Central Canada and work with VP/DCM's in setting the targets on significant KPIs to reduce cost, improve quality and increase customer satisfaction Key Accomplishments:
• Optimized the network by closing one of the facilities and moved the work to another location.
• Improved Thruput (efficiency) in Central Canada by 10% by aligning goals, setting right metrics, and improving processes. Exceeded process improvement financial savings target by 50%
• Turn around the plant and reduce cpc (cost per case) by 13% in 6 months, $2M in savings
• Improved 30% Thruput (efficiency) by changing processes, scheduling and fl

Own and manage the Variable Cost Productivity (VCP) of the site by collaborating with finance on setting budget and establishing KPIs. Responsible for leading & implementing lean six sigma improvement at Markham manufacturing plant. Lead the warehouse team of 30 people and implemented new ERP system for warehouse. Key Accomplishments
• New Plant Start Up- Moved two plants from two different locations into a new plant, successfully completed the project on time without loss of production hours and no safety incident. Managed all aspects including communication, getting buy in, building project plan, completing shop floor layout establishing flow and standards.
• Delivered $3.2 million in annualized productivity savings in 2013 and $3.6 million in 2014
• Turnaround warehouse operations by implementing WMS, setting KPI's and building the team. Key member of site leadership team to implement Oracle ERP system.

Responsible for leading the continuous improvement activities in operations & sales. Train people on lean six sigma tools and techniques. Implement systems like Andon clock with automated tracking tools. Key Accomplishments
• Improved On Time Shipment from 55% to 95% within 2 years by balancing the customer demand with operations capacity and streamlining the flow by removing bottlenecks
• Implemented Takt time and Andon clocks in operations to set baseline and streamline the flow in operations. Standardized the work and built accountability in the system, this improved capacity by more than 50% and reduced the cycle time by more than 30%, resulting in $2M in savings
• Successfully made the business case to buy two automated machines (laser and robotic brake press) worth $1.5 million to improve efficiency and productivity

Supervise the activities of 9 Quality Inspectors, 1 co-op student and 1 quality analyst in ISO 9000 and ISO 14000 environment ensuring that tasks are conducted consistently, efficiently and meet the needs of the business. Responsible for quality control, assurance and improvement activities in the plant. Handle complaints, analyze the root causes and provide technical support to operations team to eliminate the defects. Key Accomplishments:
• Reduced defects by 50% that resulted in savings of more than $500,000.
• Built a real time defect tracking database to provide communication and deliver results

Lead the successful turnaround of manufacturing operations at Motor Grader plant. Supervised 3 process programmers, 2 industrial engineers and an industrial engineering co-op student and indirectly supervised 4 production supervisors Key Accomplishments:
• Balanced Cab Line, productivity increased from 55% to 95%, improved utilization from 65% to 97% and reduced cycle time from 6.8 hours to 4.7 hours; savings of $375,000 per year
• Redesigned paint racks to improve load density resulting in savings of $300,000 per year

Design brackets, steps, mounting plates in part design and sheet metal workbench for molded components to fit on motor grader according to GD&T standards in Catia V5 (CAD software)