Chirag Bhatt
Quakers Hill,NSW
Summary
Dynamic and results-driven Production Manager with over 25 years of experience leading end-to-end Production, operations & projects. Proven expertise in strategic planning, quoting, scheduling, and delivering on time and within budget. Adept at leading cross-functional teams, mentoring project managers, and implementing process improvements that drive efficiency, profitability, and premium quality outcomes. Strong technical foundation in manufacturing and fabrication, coupled with a practical, solutions-focused mindset. Committed to continuous improvement, client satisfaction, and aligning all operational activities with brand values and business goals.
Production management professional knowledgeable about allocating resources, optimizing production and increasing output with hands-on and dedicated approach. Articulate and professional problem-solver with good relationship-building abilities. Proficient in planning and implementing innovative production strategies.
Overview
24
24
years of professional experience
Work History
Production Manager / Operations & Supply Chain Manager
Austdac Pty Ltd
07.2021 - 02.2025
- Company Overview: A global company headquartered in the United States, with an annual turnover of approximately $40 million. Specialising in mining and material handling solutions, the company is a leading international customer of conveyor monitoring, control, and communication systems—renowned for its proven track record of successful installations across the globe.
- Directed full-spectrum operations across manufacturing, project execution, and field service—covering strategic planning, master scheduling, budgeting, and resource allocation.
- Led a 40+ member team across production, warehouse, and service, with five direct reports—fostering a culture of ownership, agility, and continuous improvement.
- Delivered 98% on-time performance for ATO and ETO projects over 12 months through capacity planning, shift scheduling, and real-time work prioritisation.
- Launched a Make-to-Stock (MTS) program based on 5–10 years of data, improving delivery performance by 20% and boosting inventory accuracy.
- Introduced Kanban systems and integrated 5S with a zone-based tool register—enhancing shopfloor efficiency and reducing non-value-added activity.
- Implemented Advanced Planning & Scheduling (APS) tools, cutting lead times by 20% and increasing visibility and throughput.
- Applied lean principles—VSM, takt time alignment, custom jigs/fixtures—achieving a 25% gain in production efficiency.
- Reengineered floor layouts and job staging to reduce WIP by 35% and improve flow, safety, and material handling by 40%.
- Rolled out visual management boards and live dashboards (OEE, utilisation, progress), driving transparency and quick decision-making.
- Authored and standardised SOPs and work instructions, reducing rework by 30% and improving first-pass yield.
- Strengthened cross-functional alignment across Design, QA, Procurement, and Engineering for seamless project handovers.
- Managed JIT procurement and logistics strategies, reducing inventory holding costs by 15% while ensuring continuity of supply.
- Led WHS programs including toolbox talks, audits, risk assessments, and training—achieving zero lost-time injuries over 24 months.
- Delivered fast-tracked, high-spec projects and coordinated technician and subcontractor resources for SLA-driven field service work.
- Oversaw cost centres across labour, materials, and third-party services, ensuring fiscal discipline and operational efficiency.
- Developed KPI frameworks for throughput, quality, and labour utilisation—boosting productivity by 18% and labour efficiency by 22%.
- Championed continuous improvement via Gemba walks, RCA, and staff-led initiatives—delivering 15+ projects annually.
- Designed and implemented a Skills Matrix across the production team, building multi-skilled capabilities and resilience.
- Established preventive maintenance schedules aligned with OEM standards; supported CAPEX planning for equipment upgrades.
- A global company headquartered in the United States, with an annual turnover of approximately $40 million. Specialising in mining and material handling solutions, the company is a leading international customer of conveyor monitoring, control, and communication systems—renowned for its proven track record of successful installations across the globe.
- Created streamlined production schedules and collaborated with production employees to communicate objectives and goals.
Production & Warehouse Manager
Electra-loom Pty Ltd
03.2020 - 06.2021
- Company Overview: An Australian company operating with lean manufacturing principles, specialising in the production of electrical wire looms and harnesses for the transport and industrial equipment sectors. Offers end-to-end outsourced wire assembly solutions, including design support, material sourcing, and manufacturing process development.
- Led a team of 30 employees, including three direct reports, managing recruitment, training, rostering, and performance evaluation.
- Negotiated and secured 8+ supplier agreements improving material flow and reducing lead times by 15%.
- Managed overseas supplier relationships for cost-effective sourcing of critical materials and consumables.
- Led cross-department collaboration for procurement forecasting, contract lifecycle tracking, and CAPEX sourcing.
- Developed and managed daily and weekly production schedules, aligning manufacturing output with sales demand.
- Oversaw repair and service operations, including diagnostics, maintenance scheduling, and equipment performance tracking to ensure minimal downtime and rapid turnaround.
- Coordinated preventive maintenance schedules for critical production and testing equipment, ensuring maximum uptime and equipment reliability.
- Worked closely with maintenance technicians and external vendors to resolve complex equipment issues and ensure parts availability.
- Controlled budgets, procurement of tools, consumables, and spare parts, aligned with production and maintenance needs.
- Supervised warehouse operations, including inbound/outbound logistics, inventory accuracy, and transportation cost optimization.
- Implemented Lean practices such as Value Stream Mapping, Time Study, and Change Management to improve efficiency and reduce waste.
- An Australian company operating with lean manufacturing principles, specialising in the production of electrical wire looms and harnesses for the transport and industrial equipment sectors. Offers end-to-end outsourced wire assembly solutions, including design support, material sourcing, and manufacturing process development.
Production Leader
Ubeeco Packaging Solutions Pty Ltd
03.2019 - 03.2020
- Company Overview: A global company with 108 sites worldwide and an annual turnover of approximately $30 million, specialising in the delivery of customised packaging solutions—including timber pallets, skids, cases, and crates—tailored to meet each customer’s unique requirements.
- Managed a team of 45 employees, including 5 direct reports, overseeing staff recruitment, training, rostering, and performance management.
- Actively contributed to factory planning for ATO, MTS, and ETO production models, ensuring on-time delivery.
- Identified and resolved production bottlenecks, minimizing downtime and optimizing output.
- Managed BOM updates, production order changes, and returns handling.
- Collaborated with maintenance personnel to plan and schedule routine maintenance tasks for production lines and packaging equipment.
- Monitored machine performance and coordinated with technicians to minimize unplanned breakdowns and improve equipment availability.
- Assisted in maintaining equipment history records and supported root cause analysis (RCA) on recurring faults.
- Managed logistics, including inbound/outbound shipping and distribution, while resolving day-to-day operational challenges.
- A global company with 108 sites worldwide and an annual turnover of approximately $30 million, specialising in the delivery of customised packaging solutions—including timber pallets, skids, cases, and crates—tailored to meet each customer’s unique requirements.
- Increased assembly line efficiency from 64% to 97% through strategic process improvements and better coordination between production and maintenance.
- Improved DIFOT (Delivery In-Full, On-Time) from 70% to 90%, enhancing customer satisfaction and service reliability.
- Evaluated manufacturing equipment for safety and functionality with regular inspections and preventative maintenance.
- Monitored workers on site during production activities for safety procedures compliance.
- Assembled products according to changing daily work orders and specific customer needs.
- Updated production metrics and facilitate regular team communication.
- Used problem-solving and issue-resolution skills to promptly and successfully address production problems.
- Trained new production staff members on safe and efficient production procedures and proper machine operations.
- Investigated processing errors and malfunctions, resolving issues with minor machine repairs.
- Examined incoming materials and compared to documentation for accuracy and quality.
- Prepared reports and technical documentation of day-to-day production processes.
- Reviewed production schedules and streamlined processes.
- Maintained organized work area by cleaning and removing hazards.
- Inspected products and machines to maintain quality and efficiency.
- Met production targets and tight deadlines by collaborating closely with team members.
- Calibrated machines to maintain required productivity levels and adherence to quality standards.
- Collaborated with other departments to optimize production workflows.
- Tested products or subassemblies for functionality or quality and troubleshot problems with equipment, devices, or products.
- Made sure that products were produced on time and are of good quality.
- Performed general equipment maintenance and repair to minimize downtime.
- Organized and prepared workstations and materials needed for operations to maximize productivity.
Production Manager
Gerard Lighting Pty Ltd
08.2016 - 03.2019
- Company Overview: A 600-employee operation delivering world-class lighting design, engineering, manufacturing, and distribution. The company brought to market Australia’s most comprehensive range of sustainable lighting solutions, tailored for key sectors including mining, stadiums, and roadways. The business has since been restructured into two separate entities: Signify and Schréder Australia.
- Managed an assembly team of ~40 with 2 direct reports, including staff training, performance management, and coaching.
- Ensured WHS compliance; conducted accident investigations and root cause analyses to drive continuous improvement.
- Developed and maintained weekly, monthly, and quarterly production schedules, meeting customer delivery timelines.
- Implemented lean manufacturing practices, including Value Stream Mapping, 5S, and Kaizen, to reduce waste and increase flow.
- Increased production efficiency by 20%, reducing downtime and improving overall equipment effectiveness (OEE).
- Worked closely with the maintenance team to plan and coordinate preventive maintenance for production machinery, reducing unexpected breakdowns.
- Supported scheduling of maintenance windows and tracked downtime metrics to improve maintenance efficiency and reduce repair costs.
- Led cost-reduction initiatives while maintaining quality standards.
- Oversaw inventory planning and procurement to ensure timely material availability and reduce overstock.
- Collaborated with cross-functional teams to resolve production challenges.
- Tracked and analysed key performance indicators (KPIs) to support data-driven decisions.
- A 600-employee operation delivering world-class lighting design, engineering, manufacturing, and distribution. The company brought to market Australia’s most comprehensive range of sustainable lighting solutions, tailored for key sectors including mining, stadiums, and roadways. The business has since been restructured into two separate entities: Signify and Schréder Australia.
- Improved assembly line efficiency from 55% to 78%.
- Reduced equipment downtime by integrating preventive maintenance planning into daily operations.
- Managed continuous improvement initiatives to drive gains in quality, flow, and output.
Production Shift Leader
Kellogg’s Australia Pty Ltd
06.2013 - 08.2016
- Company Overview: Australia produces a substantial volume of cereal, with its Botany factory in Sydney manufacturing approximately 42 million kilograms annually.
- Managed a production team of 20, ensuring quality output and optimized processes.
- Scheduled tasks and monitored performance against quality and efficiency standards.
- Ensured efficient use of resources including labor, materials, and machinery.
- Implemented GMP, HACCP, SQF, ISO 9000 & 14000 standards.
- Solved production and quality issues through CAPA.
- Oversaw shift planning, changeovers, breakdown response, and start-up activities.
- Planned, scheduled, and tracked preventive and corrective maintenance for all production assets and utilities.
- Maintained and troubleshot systems including SCADA, pneumatic systems, silos, and furnaces.
- Ensured compliance with Lockout/Tagout (LOTO) procedures and safe work practices.
- Coordinated with external vendors for specialized maintenance tasks and ensured timely completion.
- Managed maintenance and production budgets, reducing energy and waste costs.
- Conducted WHS inspections and improved safety culture.
- Australia produces a substantial volume of cereal, with its Botany factory in Sydney manufacturing approximately 42 million kilograms annually.
- Increased productivity by 90% by optimizing schedules and equipment uptime.
- Reduced rice rejection and improved OEE through Yellow Belt Lean project.
- Improved yield and quality using PFMEA analysis and maintenance reliability strategies.
- Inspected products and machines to maintain quality and efficiency.
Manufacturing Production Supervisor
SMC Pneumatics Pty Ltd
07.2007 - 03.2013
- Company Overview: SMC is a global leader in the manufacturing of pneumatic control devices that utilise compressed air for automation, offering solutions including pneumatic cylinders, control systems, fabrication, and welding.
- Assessed and optimized each production station for maximum efficiency.
- Scheduled production and monitored workflow progress.
- Trained operators on safe machinery usage and enforced safety protocols.
- Led preventive maintenance activities for CNC machines, manual lathes, and pneumatic assembly stations.
- Developed daily and weekly maintenance routines, working with technicians to reduce downtime and increase equipment reliability.
- Managed operations in the machine shop and on the assembly line.
- Conducted risk assessments and root cause analysis for incidents and near misses.
- SMC is a global leader in the manufacturing of pneumatic control devices that utilise compressed air for automation, offering solutions including pneumatic cylinders, control systems, fabrication, and welding.
- Reduced changeover times from 3–5 hours to 1–2 hours using SMED techniques.
- Won Best Practice Award for driving safety and maintenance culture improvement.
Production & Maintenance Manager
Philips India Ltd
11.2000 - 01.2007
- Company Overview: Philips India is a leading manufacturer of tube lights, bulbs, halogen lamps, and LED lighting solutions, operating a continuous 24/7 production facility to ensure consistent supply and quality.
- Oversaw production and maintenance teams, managing end-to-end factory operations.
- Maintained inventory, production schedules, WIP tracking, and budgeting.
- Directed equipment maintenance programs, including routine servicing, corrective actions, and equipment upgrades.
- Implemented maintenance planning through JD Edwards ERP system, managing work orders and procurement.
- Coordinated with vendors on parts procurement, equipment specifications, and maintenance timelines.
- Applied Lean tools like Kaizen, JIT, SPC, and FMEA for continuous improvement.
- Enhanced productivity through improved energy and raw material utilization.
- Maintained ISO 9001 compliance and oversaw customer complaint resolution.
- Philips India is a leading manufacturer of tube lights, bulbs, halogen lamps, and LED lighting solutions, operating a continuous 24/7 production facility to ensure consistent supply and quality.
- Improved yield from 70% to 93% via Green Belt Six Sigma project.
- Led the fastest VTL production line installation, achieving full operation within record time.
Education
Mechanical Engineering -
01.1996
Advanced Diploma in Mechanical Engineering - undefined
TAFE
01.2010
Skills
- Leadership & Team Empowerment
- Inventory & Supply Chain Management
- Sales & Operations Planning (S&OP)
- Customer Focus & Strategic Thinking
- Cost Management & Budgeting
- Project Management
- Adaptability & Change Management
- Lean Manufacturing & Process Optimization
- Analytical & Organizational Skills
- Quality Assurance & WHS Compliance
- ERP/MRP Systems & Technology
- Production data analysis
- Quality assurance controls
Timeline
Production Manager / Operations & Supply Chain Manager
Austdac Pty Ltd
07.2021 - 02.2025
Production & Warehouse Manager
Electra-loom Pty Ltd
03.2020 - 06.2021
Production Leader
Ubeeco Packaging Solutions Pty Ltd
03.2019 - 03.2020
Production Manager
Gerard Lighting Pty Ltd
08.2016 - 03.2019
Production Shift Leader
Kellogg’s Australia Pty Ltd
06.2013 - 08.2016
Manufacturing Production Supervisor
SMC Pneumatics Pty Ltd
07.2007 - 03.2013
Production & Maintenance Manager
Philips India Ltd
11.2000 - 01.2007
Advanced Diploma in Mechanical Engineering - undefined
TAFE
Mechanical Engineering -
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