Yavuz Atabay
Plant Group Manager
Kocaeli
Summary
Accomplished Plant Manufacturing Manager boasting a decade of experience in production oversight and fifteen years in leadership roles across automotive industry. Adept at tracking KPIs, budget oversight, and enforcing HSE standards, promoting effective production line management. Strong partnership with team leaders to ensure timely and budget-compliant project completion.
Overview
15
15
years of professional experience
10
10
Certifications
2
2
Languages
Work History
Production Manager
Ulus Metal, Gebze
01.2024 - 01.2025
- Supervised 250 blue-collar personnel in manufacturing shock absorbers and components for OEMs and Tier 1 clients. Oversaw transfer processes and progressive press lines for efficient metal forming. Led operations for spot, resistance, and mag welding on lower parts and brackets. Maintained strict adherence to IATF 16949 standards during production processes.
- Drove production operations for maximum workflow efficiency and resource utilization. Led lean management initiatives, resulting in significant reductions in waste. Managed maintenance strategies to boost equipment reliability and reduce downtime. Established continuous improvement processes to promote operational excellence across teams.
- OEE assessment of manufacturing lines
- Managed production budget effectively, optimizing resources and minimizing costs. Ensured compliance with safety regulations through diligent tracking of HSE actions. Identified cost-saving opportunities by monitoring budget performance meticulously. Enhanced workplace safety standards by coordinating follow-ups on HSE initiatives.
- Overseeing Lean Management initiatives for deployment on lines
- Evaluate scrap reduction efforts and execute production development strategies.
- Orchestrating and supervising quality development and line implementations.
- Commissioning development projects in production sector
- Oversee and evaluate maintenance teams to attain MTTR and MTBF goals.
- Directed internal operational standards while enhancing productivity targets.
- Optimized production processes, job responsibilities, and quality assurance protocols.
- Elevated overall productivity through identification of bottlenecks in production process and suggesting impactful solutions.
- Directed continuous improvement efforts aimed at maximizing quality, flow, and output.
- Executed root cause analysis on production problems, formulating corrective measures to eliminate future
- Managed team budgets to maintain project timelines and prevent resource wastage.
- Managed quality control processes, upholding stringent adherence to industry standards and regulatory guidelines while securing high levels of customer satisfaction.
- Elevated production efficiency by refining processes and adopting lean manufacturing strategies.
- Coordinated with diverse teams to facilitate timely delivery of high-quality products meeting customer specifications.
Manufacturing Group Manager
Autoliv, Gebze
08.2018 - 03.2023
- Managed five production divisions: Assembly, Stamping, Heat Treatment, Ni/Cr Plating, and Overmolding. Oversaw cross-functional team management as AMG Manager to achieve comprehensive manufacturing success. Reported directly to Autoliv Turkey Plant Manager and Europe Seat Belt Component Stamping Operational Director.
- Directed a team of 25 professionals, including three production chief engineers and five quality foremen. Supervised five production leaders, five quality production engineers, and five maintenance engineers. Managed two customer quality engineers and five process engineers to ensure operational efficiency.
- Responsibilities of Assembly, Stamping, Heat Treatment, Ni/Cr Plating, and Overmolding division budgets and investments.
- Oversaw operations of 13 stamping presses ranging from 150T to 600T. Managed production of seat belt retractor frames using over 80 progressive tools. Led a team of 50 press operators to ensure efficient workflow and quality output.
- Executed assembly processes for stamped components, including metal forming and welding. Utilized thread forming techniques and operated eccentric presses efficiently. Managed both semi-automatic and automatic assembly lines for optimal production. Collaborated with 160 operators and 3 team leaders to enhance workflow. Supported production operations under guidance of 1 production chief.
- Led team of six heat treatment technicians and one team leader in operating large tunnel oven for hardened steel buckles. Managed heat treatment processes to ensure quality and efficiency of production. Coordinated maintenance schedules for equipment to minimize downtime. Trained staff on safety protocols and operational procedures to enhance workplace safety.
- Facilitated transfer of Ni/Cr plating division from NRC plant within six months. Commissioned facility to enhance internal production capabilities previously handled externally. Collaborated with one lead chemist and four process engineers on successful transition. Managed team of 45 operators in coating division to ensure seamless operations.
- Operated 15 six-axis robot injection machines for efficient overmoulding processes. Applied PP material plastic coating to 240,000 seat belt buckles daily. Supervised a team of 1 production leader and 54 operators to ensure operational excellence.
- Leading and achieving KPIs across divisions regarding safety, quality, cost efficiency, Lean Management, delivery, and team motivation.
- Notable Achievements:
- Commissioned and launched non-operator assembly lines, enhancing operational efficiency. Eliminated direct labor in assembly by optimizing line balancing and implementing automation projects. Achieved significant savings through one-piece flow processes involving twelve operators.
- SMED and TPM Studies (Combination of ergonomics and motivation to enhance operator performance and reduce absenteeism.)
- Initiated 3M Euros Fully Automatic Ni/Cr Plating Line.
- Fostered a culture of innovation by encouraging idea generation from all team members.
- Spearheaded cost-saving initiatives by analyzing expenses, identifying inefficiencies, and recommending practical solutions.
- Mentored junior team members by providing guidance, support, and constructive feedback on their performance.
- Coordinated cross-functional teams for successful completion of major manufacturing projects on time and within budget.
- Implemented safety protocols leading to a significant decrease in workplace accidents and incidents.
- Conducted thorough root cause analysis for recurring issues in the production process to eliminate reoccurrence of defects or errors.
- Collaborated with engineering teams to develop new products, improve existing designs, and enhance manufacturability.
Production Manager
Pimsa Adler, Gebze
10.2016 - 08.2018
- Supervised PA2 production operations across two workshops serving global vehicle manufacturers. Guided three white collars and 163 blue collars towards achieving high production standards. Focused on producing cabin carpets with integrated PU and acoustic flooring components. Maintained plant efficiencies by systematically monitoring and improving machinery and processes. Reached OEE targets through comprehensive operational management strategies. Facilitated new product introductions via technological assessments and reliable cost analyses. Orchestrated AM Module implementation alongside root cause analysis for resolving quality issues. Drove productivity through strategic kaizen initiatives, 5S practices, and lean manufacturing.
- Boosted overall productivity by recognizing bottlenecks in production process and delivering targeted solutions.
- Analyzed root causes of production issues, establishing corrective actions to ensure prevention of future incidents.
- Amplified production efficiency by restructuring workflows and adopting lean manufacturing strategies.
- Adopted automation and tech enhancements for production floor, boosting operational efficiency and minimizing labor costs.
Manufacturing Chief
Federal Mogul Powertrain, Sapanca
01.2014 - 10.2016
- Directed piston ring production line, ensuring smooth operations from foundry through inspection. Implemented TPM practices to optimize performance of production equipment. Commissioned and integrated new production machines internationally and domestically. Executed productivity enhancement projects focused on lean management methodologies. Conducted detailed scrap rate analysis to elevate product quality and lower losses. Created effective production planning strategies, leveraging SMED for increased efficiency. Streamlined multiple stages of piston ring manufacturing process for improved workflow. Supported daily operations as deputy for piston ring production manager.
- Utilized lean methodologies to optimize workflow, elevate quality, and decrease waste.
- Performed root cause analysis evaluations to uncover areas for optimization within manufacturing processes, contributing to improved efficiency and diminished defects.
- Directed production team, maintaining production schedules to achieve strict deadlines.
- Engineered strategic plans for manufacturing operations, harmonizing with company objectives to propel sustainable growth.
- Maintained adherence to safety regulations at all times, performing regular inspections and encouraging a culture of safe work practices among employees.
- Analyzed and suggested innovative technology investments to enhance efficiency, decrease costs, and strengthen overall production capabilities.
Electroplating and Surface Treatment Engineer
Federal Mogul Powertrain, Sapanca
04.2010 - 01.2014
- - Hard chrome electroplating, phosphate coating, tin plating production lines
- - Hazardous waste chemical treatment plant and
- - Follow-up daily, weekly, monthly required piston ring production volumes
- - Leading to scrap reduction teams and process improvement groups.
- - Leading to a flow mechanics group that aims to improve fluid performance and conduct productivity studies.
Education
Master of Science - Industrial Engineering Management
07.2015
Bachelor of Science - Chemical Engineering
01.2003
Skills
Production management
Cross functional team collaboration
Process optimization
Electroplating
IATF 16949 internal auditing
Leadership
Cost reduction
Operational efficiency
Team building
Root cause analysis
KPI monitoring
Lean production
Value stream mapping implementations
TPM management
Certification
AIAG CQI-23 Molding Process Auditor, KOBEM 2021
Timeline
Production Manager - Ulus Metal, Gebze
01.2024 - 01.2025
Manufacturing Group Manager - Autoliv, Gebze
08.2018 - 03.2023
Production Manager - Pimsa Adler, Gebze
10.2016 - 08.2018
Manufacturing Chief - Federal Mogul Powertrain, Sapanca
01.2014 - 10.2016
Electroplating and Surface Treatment Engineer - Federal Mogul Powertrain, Sapanca
04.2010 - 01.2014
Kocaeli University - Master of Science, Industrial Engineering Management
Ege University - Bachelor of Science, Chemical Engineering