Chath Karunarathna
Mount Waverley,VIC
Summary
With over a year of leadership at PPG, my focus has been on enhancing operational efficiency and quality assurance. My tenure at O'Kelly solidified my problem-solving capabilities, enabling me to effectively manage production challenges and implement quick changeovers that drive performance improvements. At PPG, the team and I have collaborated to streamline processes, ensuring sustained advancements in quality and delivery.
My commitment to quality is underscored by a Diploma in Quality Auditing, which guides my approach to overseeing production environments. In collaboration with my teams, we utilize analytical thinking and creative planning to meet our operational objectives. Our efforts are directed towards innovative methods that foster a culture of continuous improvement and operational excellence.
Overview
12
12
years of professional experience
Work History
First Line Manager
PPG Industries
07.2023 - Current
- Ensure Plant production is conducted within the Company and statutory Environment, Health and Safety regulations, and other accreditations within the PPG Guidelines
- Actively engage in EH&S programs and promote EH&S policies, procedures, and practices
- Lead and manage manufacturing initiatives in the production area in accordance with company objectives to drive and monitor production to achieve production targets, implement continuous improvement initiatives to improve operational performance
- Ensure the production outputs meet or exceed targets on a daily, weekly, monthly, and annual basis
- Continually improve productivity and operational efficiency by minimizing waste, and overtime and aids to manufacture to reduce unit costs
- Manage metrics include OTIF, Stock Availability, Forecast Accuracy, Inventory, and yield
- Sustain and manage a strong performance culture in manufacturing with all levels of employees through communication processes, skill gap analysis, and effective training solutions
- Develop and maintain an environment that allows employees to contribute to business objectives by managing standards of behaviour and performance within the work teams
- Establish and maintain a close working relationship with Manufacturing, Engineering Department, EH&S, Supply Chain and Technical departments
Production Manager
O’Kelly Group
06.2022 - 07.2023
- Prepare and manage overall budgets including capital expenditure
- Created streamlined production schedules and collaborated with production employees to communicate objectives and goals.
- Maintains high-quality levels and low waste levels by establishing and enforcing organization standards
- Maintains a safe and clean work environment
- Artwork validation and initiate first off sample. BOM creation for new products.
- Develop and prepare KPI reports for manufacturing-related activities
- Securing the supply chain for continuous manufacturing
- Drive a non-negotiable OH&S program (our people are our most important asset) Ensure compliance with all rules and regulations that apply to your workplace, to maintain a safe working environment
- Manage the HACCP program to consistently ensure compliance
- Optimize and manage the inventory level of all the raw materials and the finished goods within agreed time limits and DIFOT, including custom order lead times
- Manage and Co-ordinate the stock take program including cycle count schedule
- Produce a stock take report outlining variances with commentary
- Develop and maintain effective relationships with suppliers
- Negotiate competitive pricing and terms with suppliers
- Monitor supplier performance to ensure agreed service levels are maintained
- Counselling, and disciplining employees: initiating, coordinating, and enforcing systems, policies, and procedures
- Managed continuous improvement initiatives to drive gains in quality, flow, and output.
- Standardized production procedures, job roles, and quality assurance guidelines.
Production and Distribution Manager
Materialised Pty Ltd
11.2021 - 06.2023
- Lead and manage a team of experienced production operators and supervisors to deliver high-quality products in a timely fashion; present production data at weekly KPI meetings
- Monitor day-to-day production, warehouse, and distribution activities
- Analyze/adjust resources and procedures to increase efficiencies and reduce costs/risks
- New product introduction in conjunction with the design and sales teams; follow-up and critical path analysis
- Project management; new machine installation, circular economy projects, process improvement projects, etc
- Controlled inventory transactions to reconcile ordering processes with demand forecasts.
- Developed standard and emergency operating procedures for receiving, handling, storing, shipping and salvaging products.
- Organized financial reporting, scheduling and inventory systems to enhance productivity.
- Negotiated contracts with suppliers and customers to provide best cost and delivery terms.
- Oversaw warehouse staff and maintained efficiency in fast-paced environment.
- Reduced worker accidents by implementing improved safety standards and monitoring procedures.
Production Manager
Kenneth Ayres (Aust) Pty Ltd
07.2019 - 08.2021
- Managed continuous improvement initiatives to drive gains in quality, flow, and output.
- Effective planning, scheduling, and utilization of resources for workflow for each product line
- Finding onshore and offshore suppliers to purchase raw material
- Assessing quotes for raw material on cost-effectiveness and quality
- Provide technical and mechanical support to machine operators
- Oversaw routine maintenance programs and scheduled service to keep equipment functioning at peak levels.
- Use the technical know how to solve issues related to machinery, product development
- Coordinate sales requirements with the production team; assist sales team with information on production due dates and other technical information on products
- Coordinate with logistics companies about the vessel shipments and delivery schedules
- New product introduction: coordinate with the design and sales teams, define the critical path and follow-up the process
- Select and purchase raw materials; ensure continuous supply for efficient production workflow including weekly cycle counting, generating MRP, purchase orders and logistics.
- Determined suitable crew requirements, scheduled employees, and worked with human resources to meet changing production schedules.
- Researched latest industry trends and technologies, boosting knowledge and understanding of industrial production.
- Oversaw routine maintenance programs and scheduled service to keep equipment functioning at peak levels.
Production Manager
MAS Holdings / HELA Clothing (Sri Lanka)
07.2013 - 01.2018
- Created streamlined production schedules and collaborated with production employees to communicate objectives and goals.
- Utilized data analysis tools to identify and resolve production issues.
- Monitored inventory levels and restocking schedules to avoid production delays from unavailable materials.
- Product Development and New product induction – Liaise with technical team and sales team and analyze the market trends and develop products
- Monitored cost and quality of production
- Practiced lean manufacturing principles – Kanban, Kazan, TPM, JIT, SQDCM, 5S, Poka-yoke (Used by Toyota Production System)
- Implemented Team Leader Group Leader concept – trained Team Leaders to solve problems at the micro level to provide immediate solutions to critical problems, avoiding bottlenecks while ensuring a streamlined process, resulting in rectification of problems
- Implemented Quick Changeover project – reduced changeover time by way of simulation meetings, pre-preparation, pre-settings, and analyzing the critical path of new products
- Continuously maintained GMP in production and developed SOP's
- Studied department operations to assist with development of new or improved methods of tooling and production processes.
- Maintain quality standards
- Managed the supply chain with local and international suppliers and customers and maintained a continuous production flow
- Collaborated with the finance department to oversee inventory management process including usage assessment and forecasting
- Assisted with price quotations for new products
- Managed logistics, including efficient shipping of products considering cost-saving options
- Established relationships with local and international suppliers to source inventory cost-effectively
- Ensured service, costs, DIFOT and customer satisfaction levels were achieved
- Monitored inventory levels and restocking schedules to avoid production delays from unavailable materials.
Education
Diploma in Quality Auditing -
HBA Learning Center
01.2020
Lean Yellow Belt
MAS Holdings
Sri Lanka03-2014
Counselling for Future Leaders Certificate -
MAS Holdings
Sri Lanka04-2013
Bachelor of Science (Special) Second Class Honors-Upper Division - undefined
University of Peradeniya
01.2013
Skills
- Production Process Planning
- Team Leadership
- Task Management
- Product Design Expertise
- Market Research
- Data Analysis
- Rapid Problem Solving
- Conflict Resolution
- Effective Written Communication
- Effective Verbal Communication
- Effective Relationship Management
- Stakeholder Engagement
- Sound judgment
- Analytical Decision-Making
- Flexible Problem Solving
- Technology adaptation
- Manufacturing principles
Extra-Curricular Activities
Developed leadership and teamwork skills as vice-Captain of the Rugby team of the University of Peradeniya, Sri Lanka. Represented Sri Lanka at the UITM International Sports Fiesta in Malaysia in 2010 in Rugby. Conducted knowledge sharing workshops as a committee member of the Botanical Society of the University of Peradeniya. Raised funds and organized educational outreach projects to rural schools of Sri Lanka with the assistance of fellow students at the University (Project name: Let Them Smile)
Education Training License
- APCO member, 2019
- GMP training, 2017
- Certificate course in SAP, 2016
- Fire and Safety training Certificate, 2013
- Forklift licence.
- Confined space champion , 2024
Timeline
First Line Manager
PPG Industries
07.2023 - Current
Production Manager
O’Kelly Group
06.2022 - 07.2023
Production and Distribution Manager
Materialised Pty Ltd
11.2021 - 06.2023
Production Manager
Kenneth Ayres (Aust) Pty Ltd
07.2019 - 08.2021
Production Manager
MAS Holdings / HELA Clothing (Sri Lanka)
07.2013 - 01.2018
Bachelor of Science (Special) Second Class Honors-Upper Division - undefined
University of Peradeniya
Diploma in Quality Auditing -
HBA Learning Center
Lean Yellow Belt
MAS Holdings
Counselling for Future Leaders Certificate -
MAS Holdings
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