RAHUL R NAIR
Kerala,India
Summary
Results-driven professional with 7+ years of experience in manufacturing and e-commerce operations, skilled in SAP PM & PP modules, lean manufacturing (5S, Kaizen, TPM), and OEE performance tracking. Proven expertise in production planning, preventive maintenance, and process optimization to improve efficiency and reduce downtime. Strong leadership in managing multi-shift operations, KPI dashboards, and cross-functional coordination across production, maintenance, and logistics teams.
Overview
8
8
years of professional experience
Work history
Operations Team Lead (Central & Returns)
Taw9eel Holdings
Kuwait City
10.2023 - 11.2025
- Led a central operations team handling forward logistics, returns, and reverse logistics for an e-commerce platform.
- Introduced process improvements that reduced order delays by 20% and improved returns/replacement handling efficiency.
- Designed KPI dashboards and Excel/Power BI reports for tracking operational and maintenance performance.
- Streamlined communication between central operations, last-mile delivery teams, and warehouse staff.
- Trained and supervised team members to maintain accuracy and efficiency in order handling.
Production Executive
Walkaroo international pvt ltd
Bengaluru
06.2019 - 10.2023
- Directed end-to-end production operations across cutting, stitching, assembly, finishing, and packing departments in a large-scale footwear manufacturing setup.
- Functioned as a key SAP Production Planning (PP) end-user, managing production orders, capacity planning, and shop floor execution tracking.
- Collaborated with the demand planning and supply chain teams to align production schedules with customer demand and sales forecasts.
- Implemented Lean Manufacturing principles (5S, Kaizen, JIT) to reduce process waste, improve workflow, and boost production efficiency by 15%.
- Planned and managed shift schedules across 3 shifts, ensuring optimum manpower utilization and target achievement.
- Developed and monitored KPI dashboards (output, rejection rate, cycle time, on-time delivery) using SAP and Excel analytics for management reporting.
- Improved production efficiency and output consistency through process streamlining and time-motion studies.
- Achieved 12% scrap reduction and enhanced on-time delivery by standardizing work procedures and optimizing line balancing.
- Coordinated with quality and planning teams to ensure consistent product standards and seamless production flow.
- Oversaw material usage (rubber, PU, PVC, adhesives, fabrics) to minimize wastage and ensure cost-effective utilization.
- Trained and guided 50+ production staff to follow standard operating procedures, improve quality awareness, and maintain productivity.
- Ensured strict adherence to safety, quality, and lean process standards, fostering a continuous improvement culture.
Maintenance Supervisor
Walkaroo international pvt ltd
Bengaluru
06.2017 - 06.2019
- Supervised preventive and breakdown maintenance across multiple footwear manufacturing units, ensuring maximum machine uptime and production continuity.
- Operated extensively in SAP Plant Maintenance (PM) for maintenance notifications, work orders, breakdown reporting, spare parts tracking, and equipment master data management.
- Scheduled and executed preventive maintenance plans (PM Plans) through SAP PM to reduce unplanned downtime and improve asset reliability.
- Implemented Lean Maintenance principles and 5S practices, streamlining workflows and improving maintenance response time.
- Prepared and analyzed OEE (Overall Equipment Effectiveness) reports using SAP data to track performance, availability, and quality of key machinery.
- Collaborated with production teams to plan maintenance windows effectively, minimizing impact on shift productivity.
- Conducted Root Cause Analysis (RCA) and implemented Corrective and Preventive Actions (CAPA) for recurring equipment failures.
- Monitored key maintenance KPIs — MTTR (Mean Time To Repair), MTBF (Mean Time Between Failures), and OEE trends — to support data-driven decision-making.
- Managed spare parts inventory, ensured critical spare availability, and updated SAP PM for real-time stock visibility.
- Reduced machine downtime by 18% through optimized preventive scheduling and continuous performance monitoring.
- Supported Total Productive Maintenance (TPM) initiatives to enhance equipment reliability and operator engagement.
- Supervised and trained a team of maintenance technicians, reinforcing safe work practices, equipment care, and lean mindset.
- Contributed to installation and commissioning of new machines and calibration of critical production equipment.
- Generated SAP-based maintenance performance and OEE reports for management reviews, driving continuous improvement initiatives
Education
Bachelor of Business Administration - BCA
North East Christian University
Dimapur /2013 - /2016
Skills
- Process Optimization
- Lean Manufacturing Principles
- 5S Implementation
- Order Fulfillment Management
- Shift Planning & Staff Supervision
- Inventory Control
- ERP & SAP
- Microsoft Excel & Power BI
- KPI Dashboard Preparation (Excel / Power BI)
- Workflow Optimization & Cost Reduction
- Demand Planning & Production Scheduling
- SAP PM & PP Modules
- Cross-functional Coordination
ADDITIONAL INFORMATION
Languages: Malayalam, Tamil, Kannada, Hindi, English
Fluent
Timeline
Operations Team Lead (Central & Returns)
Taw9eel Holdings
10.2023 - 11.2025
Production Executive
Walkaroo international pvt ltd
06.2019 - 10.2023
Maintenance Supervisor
Walkaroo international pvt ltd
06.2017 - 06.2019
Bachelor of Business Administration - BCA
North East Christian University
/2013 - /2016