Çağatay Özkan
Production Team Leader
Kocaeli
Summary
Dynamic Production and Maintenance Leader with extensive expertise in the automotive manufacturing sector, skilled in managing large-scale operations in assembly and paint shop environments. Proven track record of leading cross-functional teams of up to 470 employees, consistently driving improvements in productivity, equipment efficiency (OEE), and quality performance. Proficient in preventive and predictive maintenance, digital transformation, and the implementation of Industry 4.0 technologies within complex production systems. Strong project management skills include the design, installation, and commissioning of new facilities alongside multiple partners, complemented by a commitment to lean manufacturing principles and fostering a robust safety culture that prioritizes sustainable performance improvements through data-driven strategies.
Overview
8
8
years of professional experience
7
7
Certifications
2
2
Languages
Work History
Production Team Leader
Ford Otosan
Kocaeli
04.2025 - Current
- Lead all operations of a paint shop producing 150,000 commercial vehicles annually, ensuring production targets, quality standards, and delivery timelines are consistently met.
- Drive the digital transformation of manufacturing systems, integrating automation, data tracking, and performance monitoring tools to enhance process efficiency.
- Manage a 470-person production workforce, including skill development, performance evaluation, and career progression planning to ensure high engagement and productivity.
- Oversee production budgeting, cost control, and resource allocation, achieving optimal utilization of manpower, materials, and equipment.
- Monitor and analyze production KPIs (OEE, quality rate, cycle time, scrap ratio), identify deviations, and implement corrective and preventive actions.
- Develop and execute continuous improvement projects focused on lean manufacturing, waste reduction, and process optimization to boost overall efficiency.
- Ensure full compliance with occupational health and safety (EHS) standards, conduct risk assessments, and implement safety improvement initiatives.
- Promote and sustain 5S and workplace organization principles across the workshop, maintaining a clean, safe, and standardized environment.
- Prepare, implement, and track annual production and investment budgets, ensuring financial performance aligns with company objectives.
- Launch cost-saving initiatives and material efficiency projects to reduce waste and increase profitability.
- Collaborate with cross-functional teams (quality, maintenance, logistics, and planning) to enhance production flow and overall plant performance.
Maintenance Team Leader
Ford Otosan
Kocaeli
04.2022 - 04.2025
- Managed a 120-person maintenance team in a high-volume assembly plant with a 400,000 commercial vehicle annual production capacity, ensuring equipment reliability and uptime.
- Developed and executed weekly, monthly, and annual preventive maintenance plans, optimizing equipment availability and minimizing unplanned downtime.
- Supervised design, installation, and commissioning phases of a new assembly plant, coordinating 7 partner companies and 170 on-site technicians.
- Conducted detailed failure and root cause analyses (RCA) to identify recurring issues and develop long-term corrective actions.
- Improved Equipment Efficiency (OEE) through systematic maintenance strategies and performance tracking systems.
- Led predictive maintenance programs using data-driven analysis and condition monitoring technologies.
- Oversaw digital transformation initiatives in production areas, including data tracking and monitoring systems integration.
- Acted as Kanban Master in an agile maintenance team, ensuring task flow transparency and operational efficiency.
- Planned and implemented training and development programs to enhance team competency and technical capability.
- Ensured strict compliance with safety standards (EHS) and promoted a strong safety culture within the maintenance department.
Electrical Maintenance Engineer
Ford Otosan
Kocaeli
12.2017 - 04.2022
- Led a 23-person electrical maintenance team, ensuring continuous production by maintaining and troubleshooting all electrical systems and automation equipment.
- Designed, programmed, and commissioned PLC, SCADA, and HMI systems for new and existing production lines.
- Diagnosed and resolved electrical and automation failures, performing root cause analysis (RCA) to prevent reoccurrence.
- Defined, scheduled, and executed periodic maintenance plans, ensuring full compliance with operational standards.
- Managed spare parts stock optimization, improving cost efficiency and part availability.
- Directed the integration of collaborative robots (Cobots) into assembly processes to improve productivity and safety.
- Led “Zero Stock” projects to optimize line feeding and material flow in coordination with production planning.
- Designed and implemented Pick-to-Light systems to ensure accurate and error-free part delivery to assembly stations.
- Developed smart camera vision systems for quality control and real-time defect detection.
- Drove Industry 4.0 digitalization projects, enhancing traceability, machine connectivity, and data collection systems.
- Established and maintained communication networks between automation systems, enabling data synchronization and interoperability.
Education
Bachelor's Degree - Electrical Engineering
Istanbul Technical University
06.2017
Skills
🧰 Technical Skills
Maintenance strategy development
Integrated systems knowledge
PLC programming and design
Cobot integration expertise
Root cause analysis expertise
Overall equipment effectiveness enhancement
Smart camera technology implementation
Proficient in pick-to-light operations
Digital transformation in manufacturing
Sustainability improvement initiatives
Experience in implementing total productive maintenance strategies
Commissioning and operational readiness
👥 Management & Leadership Skills
Leadership of large teams in production and maintenance
Budget Planning & Cost Optimization
Employee development
Cross-functional teamwork in production, logistics, quality and design
Performance management
Comprehensive project oversight
Kanban project management
Strategic planning
Safety program management
Collaborative team engagement
💻 Digitalization & Improvement Skills
Digital transformation in manufacturing
Data monitoring and tracking
Continuous improvement strategies
Proficient in 5S and Kaizen
Industrial IoT integration
Maintenance performance evaluation based on data
Connectivity in automation systems
Certification
6 Sigma Greenbelt
Interests
Nature trips, trekking, Electronic music, Reading personal development books, Table tennis, Volleyball
Strong Personal Characteristics
- Analytical thinking
- Strategic mindedness
- Result-oriented
- Efficiency-oriented
- Innovative
- Leadership
- Self-confident
- Courageous
Timeline
Production Team Leader
Ford Otosan
04.2025 - Current
Maintenance Team Leader
Ford Otosan
04.2022 - 04.2025
Electrical Maintenance Engineer
Ford Otosan
12.2017 - 04.2022
Bachelor's Degree - Electrical Engineering
Istanbul Technical University