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Sunny Ghai

Sunny Ghai

Director of Procurement

Fres-co System USA, Inc.

Director of Procurement at Fres-co System USA, Inc.





Fres-co System USA, Inc.

Director of Procurement

Manages multi-plant purchasing/sourcing for leader in flexible packaging systems for food, liquid and specialty markets. Responsible for procurement of all direct, indirect, energy, corporate real estate and equipment spend. Experienced in raw material sourcing including polyethylene and nylon resins, polyester and aluminum films, industrial solvents and adhesives.

Career medium 02
Career medium 01

JDSU (CommTest)

Director, Global Commodity Management | CommTest

Led GCM Team for Test & Measurement division of $1.8B communications company. Managed sourcing, cost reduction and supply risk for all direct spend including software, servers, OEM/ODM, semiconductors, optics, passives, displays, batteries, magnetics, switches and relays, electromechanicals (including interconnect, cables, PCB, plastics, die casting, machining, carrying cases / gloves), and power converters/supplies. Within first three months of hire:
* Developed processes and metrics for forward looking improvement of contract manufacturers (CMs)
* Developed commodity strategies for top 80% spend technologies.
* Implemented Approved Supplier List (ASL); re-engineered GCM organization for early New Product Introduction (NPI) engagement.
* Championed development of lean process for global approval of new suppliers and components.
* Immediately achieved up to 18% cost reduction from first quarterly negotiations.



Global Procurement & Sourcing Leader

Global Purchasing and Supplier Management
Coordinated commodity teams responsible for managing global business relationships between Alcatel-Lucent and optical suppliers. Closely led strategic sourcing of commodity categories related to R&D and NPI with Bell Labs’ domestic and international design centers. Directed major supply chain activities impacting $450M commodity spend for over $3B revenue. Negotiated Supply, IP/Development, Liability Agreements and Just-In-Time (JIT) / Vendor Managed Inventory (VMI) contracts.
* Negotiated 15 to 20% year-over-year cost reductions. Cost reductions were nearly 50% above average results achieved by peers. Developed and managed supplier strategies and supply chain risks that avoided major supply interruptions during extreme downturn in global markets.
* Recognized Top 10% “Key Performer.”

Career medium 06
Career medium 03

T-Networks (acquired by Avago Technologies)

Supply Chain Director | Manufacturing Director

Supply Chain Director (2002 - 2003)
Implemented cost-effective global supply chain strategy, salvaging otherwise unprofitable business model. Developed product cost models and methodical approach to cost reduction for this optical networking start-up. Forged key supplier relationships.
* Reduced purchased component lead-time by 66%, shortening time for design-turns from 12 to six weeks.
* Slashed material costs by 75% while improving supply chain performance and quality metrics.
* Researched, selected and implemented Visual Manufacturing ERP; developed materials lot traceability system.

Manufacturing Director (2001 - 2002)
Managed equipment installation, strategic allocation and recruitment of staff, and development of business, manufacturing and quality processes/systems.
* Oversaw rapid development and manufacture of next generation products. Successful demonstration of organization’s ability to deliver industry-disruptive technology led to $30M “Series B” VC funding round.
* Implemented work cell and 5S methodologies.
* Developed and implemented numerous business, manufacturing, and quality data processes/systems which successfully staged company for ISO 9001:2000 registration.


Cisco Systems

Supply Base Engineering Mgr | Acquisition Integrations Program Manager - Pirelli Optical Systems

Supply Base Engineering (SBE) Manager (2001)
Promoted to create SBE organization for New England Manufacturing Center. Provided technical management of NPI and quality activities for all of Cisco's optical products.
* Hired and mentored nine SBEs to globally support quality and technical management of Cisco’s suppliers for Optics Networking Group (ONG) Business Unit. Co-developed optical module outsourcing strategy with commodity teams.
* Managed highly strategic optical amplifier and transponder outsourcing programs, resulting in $100M agreement with Corning for future joint development and collaboration.

Acquisition Integration Program Manager (2000)
Managed manufacturing acquisition integration of various optical systems companies including Pirelli Optical Systems, Qeyton Systems, Monterey Networks and Cerent.
* Fast tracked $37M budget for capital equipment expansion into 684K SF facility in Salem, NH.
* Played key role in both hiring and acclimating first 50 employees, integrating four acquisitions and consolidating global manufacturing of plants in France, Italy and US into Salem facility. Resulted in rapid operations start-up and First Customer Ship (FCS) in four months from plant possession.

Career medium 05
Career medium 01


Manufacturing Strategy, Planning & Facilities Mgr

Manufacturing Strategy, Planning & Facilities Mgr (1999 - 2000)
Developed manufacturing/quality strategies for product development, capital expansion, cost reductions and quality improvements. Managed $10M capital budget and 100K SF manufacturing facility.
* Developed formal training and certification programs resulting in 75% reduction in training costs.
* Championed lean manufacturing; developed and taught cellular manufacturing workshops. Initiated 5S, cycle time and set-up time reduction programs and bottleneck management methodologies.

Manufacturing Manager (1997 - 1999)
Led operational turnaround by optimizing manufacturing processes and implementing numerous Quality Systems initiatives (GR&R, Quality Data System and Document Control). Supported implementation of Promis ERP.
* Achieved record profits. Increased productivity, yield and on-time delivery; salvaged a critical MCI account.
* Led new product development projects, resulting in customer qualification and highest first-pass yield.


Artysen Technologies (Acquired by Emerson Network Power)

Contract Manufacturing Manager

Managed strategic outsourcing initiatives; developed sourcing strategies; negotiated Manufacturing Services Agreements (MSA).
* Introduced over one hundred DC/DC power converters into contract manufacturing.
* Reduced product cost by 45% from start-up to steady state while improving product quality

Career medium 03
Career medium 02

Avex Electronics (Acquired by Benchmark Electronics)

Manufacturing Manager

Grew contract manufacturing account with Polaroid Corporation to profitable 4-shift, 85 employee, $25M business.
* Awarded ISO 9000 registration on initial audit within eight months of plant startup.
* Launched formal Continuous Improvement Programs (CIP) resulting in increases in profit of 600%, production output by 300%, process yields by 30% and reduced labor costs by 35%.


Metraplex Corporation (Acquired by Herley Industries)

Manufacturing Manager

Ford Electronics (Now Visteon)

Manufacturing Management

Held various roles in Manufacturing Management leading teams of up to 80 employees.

The Johns Hopkins University

Penn State University

BS, Engineering

Parkland High School (Orefield, PA)