Ahamed Usama Unais

Kevilton Electrical Products Pvt. Ltd. is one of the leading manufactures of electrical switches, sockets and lighting products. I led the production department in the manufacturing plant in Ratmalana, Sri Lanka. - Directed daily production operations across injection molding, metal stamping, automated and manual assembly, and subcontracting, managing a team of 80 employees, including 5 direct reports. - Spearheaded lean process improvements in LED bulb assembly, achieving over 100% capacity increase and significantly enhancing production efficiency. - Actively developed team capabilities across the value stream to drive performance and skill growth. - Expanded production capacity by 20% through establishing new subcontractor relationships. - Fostered a culture of continuous improvement by implementing a Kaizen rewards system, encouraging proactive, team-driven process enhancements. - Led enhancements to the MRP supply chain process in SAP, effectively reducing stockouts and overstock issues through more accurate materials planning.

- Led Injection Molding, Tool Room, and Metal Stamping divisions, overseeing end-to-end production, tool maintenance, and process optimization. - Directed the Tool Room’s maintenance and repair operations for tools and dies, utilizing both in house and external workshops. - Gained hands-on expertise in SolidWorks for CAD drawings and applied CNC, lathe, surface grinding, wire cutting and welding techniques to support precision repairs. - Drove waste reduction initiatives, reducing excess material usage in plastics manufacturing through design changes and process optimization. - Used the lean 8-step problem-solving method to increase rolled throughput yield to 95%, identifying and reducing defects across processes. - Created and managed annual capacity and CAPEX budgets, ensuring alignment with production goals and financial targets. - Planned and monitored the 4Ms (Man, Machine, Material, Method) to optimize manufacturing processes and resource utilization. - Minimized inventory discrepancies by identifying transactional errors, implementing cyclical counts, and driving process improvements. - Enhanced Overall Equipment Effectiveness (OEE) to 80%, reduced plastic defects to below 1.8%, and minimized material waste to under 0.3% through autonomous and preventive maintenance programs. - Introduced and implemented one-point lessons across the factory to streamline training, improve knowledge retention, and enhance team performance. - Conducted technical training for machine operators on scientific molding principles, improving skill sets and process understanding. - Led a digital transformation project, replacing a paper-based production logging system with an app-based solution to streamline operations and improve data accuracy. - Served as an internal auditor for ISO and 5S audits, ensuring compliance with quality and organizational standards within the factory.

- Headed Injection Molding and Metal Stamping Divisions, overseeing end-to-end production and team performance. - Implemented initiatives to reduce 15 metric tons of aging material inventory (plastics and metal strips), enabling the company to utilize unused inventory, optimize storage, and decrease waste. - Executed a project to reduce cycle time for injection-molded items, applying targeted improvements that increased the Performance metric in OEE. - Handled daily operations in SAP Production Planning, including BOM creation, routing, and production workflow management. - Led a focused improvement project that boosted assembly line capacity by 36% through the implementation of an automated carton erector machine. - Expanded injection molding production capacity by 30% by strategically onboarding and managing three new subcontractors. - Established Standard Operating Procedures (SOPs) for comprehensive storage management and material handling across the factory, enhancing efficiency and compliance. - Directed a digital transformation initiative by developing a shuttle booking app, streamlining transport resource management.

- Conducted feasibility studies, cost analysis, and managed all aspects of the LED plant construction project from initiation through to successful inauguration. - Collaborated in R&D for a new LED product range, leading supplier negotiations, performing technical evaluations, and conducting comprehensive market surveys