Saji John

I’m a “Performance Driven Professional” with over 19 years of hands-on experience in the manufacturing process of optical discs. I oversee plant operations with a strong focus on top-line and bottom-line profitability, ensuring optimal utilization of resources through disciplined, 24/7 production execution.

I’m skilled in production planning, executing schedules, and monitoring performance through key production KPIs such as OEE, yield, throughput, wastage, and labor productivity. I solve quality issues for DL2P, ISDL, DVD, and CDR products using DMAIC and FMEA, and I continuously improve operations with TPM, 5S, Kaizen, Poka-Yoke, DOE, and process mapping.

I also lead efficiency improvements through Six Sigma projects and Break Through Redesign efforts, including reducing overall polycarbonate waste by 50% and improving OEE and cycle-time performance on multiple lines. From managing spare parts and SOP/OCAP preparation to training junior employees and coordinating with suppliers, I aim to exceed targets by leading by example—and delivering sustainable results.