Karthik Kumar

Operations Manager

19years of work

8years leading teams

3.2years average tenure

7years at Apollo Tyres Ltd.

Overview

Manufacturing and industrial engineering leader with 19+ years of experience in production management, industrial engineering, and manufacturing excellence. Hands-on experience across assembly productivity, line balancing, capacity and manpower planning, OEE and loss analysis, and continuous improvement using Lean, TPM/TQM, Kaizen, RCA/8D, and quality/audit readiness. Leads shop-floor teams and capability-building programs focused on safety, quality, and sustained operational efficiency.

Phone

Timeline

Associate Manager (Industrial Engineering & Manufacturing Excellence) · Lead

Apollo Tyres Ltd. · Full-Time

May 2019 to Present 7 Years 6 Months Chennai In office

Lead the manufacturing excellence agenda for an assembly business unit with a 300+ person team, focusing on TPM and daily management systems. Perform time and motion studies, process flow analysis, line balancing, and capacity/manpower planning to reduce losses and improve throughput. Deliver shop-floor training (BBS and QCC/QC Story) and standardize in-process quality checks to sustain zero non-conformances in IATF/ISO audits.

Manager · Lead

Rialto Enterprises Pvt. Ltd. · Full-Time

Nov 2017 to Apr 2019 1 Year 5 Months Chennai In office

Designed a manpower optimization approach across shifts to balance permanent and contract labour and close deployment gaps. Partnered with production teams to raise and sustain line efficiency while improving process flow and ergonomics by analyzing operator movement and layouts. Facilitated SMETA and ISO audits with compliant documentation and used RCA/corrective actions to reduce quality issues and rework.

Deputy Manager · Lead

Flamagas India Pvt. Ltd. · Full-Time

Dec 2015 to Oct 2017 1 Year 10 Months Chennai In office

Drove a throughput turnaround in the assembly area by reallocating manpower and optimizing machine utilization within a short timeframe. Reduced scrap by strengthening operator capability at quality checkpoints and introducing preventive maintenance routines. Introduced departmental KPIs for safety, output, and downtime, and used OEE analysis to identify equipment bottlenecks and improve availability.

Team Member · Middle

Apollo Tyres Ltd. · Full-Time

Feb 2011 to Dec 2015 4 Years 10 Months Chennai In office

Supervised shop-floor staff on high-volume production lines, ensuring daily output targets were met. Monitored production data in real time to detect inefficiencies early and adjust before shift underperformance. Implemented safety practices to reduce incidents and supported quality improvement initiatives focused on defect prevention and audit readiness.

Engineer · Middle

MRF Tyres Ltd. · Full-Time

Apr 2010 to Jan 2011 9 Months Hyderabad In office

Supported brownfield manufacturing setup and commissioning by coordinating equipment readiness, production trials, and manpower deployment. Trained new recruits on machine handling and safety protocols to improve onboarding effectiveness. Managed scheduling to meet order deadlines while resolving coordination delays that reduced unplanned downtime.

Officer · Middle

Exide Industries Ltd. · Full-Time

Jul 2007 to Mar 2010 2 Years 8 Months Hosur In office

Implemented training-needs-driven operator capability programs that improved retention and increased team productivity. Reduced rework and scrap by applying SOP-driven quality checks. Led 5S and workplace safety initiatives to maintain clean, hazard-free operations and improve overall shop-floor standards.

Technical skills

Management

Microsoft Office

Kanban

Job preferences

Work permits: India

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