Ref. No. : CA - 27744 (Production - Moulding with 20 years in Plastic Industry)

Gender
Male
Age
42 Years
Designation
Department Head
Highest Education Level
Masters - Degree
Current Gross Salary
INR 2500000 /Annum
Notice Period
30 Days
Education Details
MBA From Operations & Marketing (Part-time)ICFAI University in 2010 with Grade A

PG-Dip (Plastics Engg.) From Central Institute of Plastics Engg. and Technology (CIPET) India in 1999 with Grade A

Bachelor of Engineering (Mechanical) From A.C. College of Engineering, Tamil Nadu, India with 1998 with 70%

12th in 1994 with 94%

10th in 1992 with 94%
Skill Sets
Holds honor of State First Rank in X std and University All India Rank in PG
Very Good Trainer in Plastics: conducted many corporate training programs for factory
people, (esp.Basic principles of Injection Molding,Time study, Motion study, SMED, FMEA analysis, JIT, POKA YOKE, MTBF, MTTR, Pareto and RCA, SPC (Process capability), DOE, 5S, etc)
Strong Problem solving skills, Analytical skills and Technical skills.
Believer in perfection oriented performance and life long learning
Able to work independently with minimal supervision.
Very keen and strong at documentation and record keeping.
Computer Savvy: Fluent @ Microsoft Word, Excel, PPT

 

Work Experience
20 Year(s)

 

Work Experience Details
Consultant
Since Aug 2018
Company Profile: Leading Plastic Product Manufacturing company.
Job Profile:
working for the Plastic Molded Furniture Division and PET Bottles division

Head - Operations
2010 to June 2018
Company Profile : Automotive Plastic products manufacturing as well as PET rigid containers, caps and closures and PET preforms manufacturing for specialty packaging segments.

Manager – Project Equipment Sales
2005 to 2010
Company Name : L&T Plastics Machinery Limited
Company Profile : Manufacturer of molding machines and entire set of auxiliary equipment's viz., Material driers, Mixers, Chillers, raw material handling equipment's for the plastic processing industry.

Deputy Manager – Maintenance
2004 to 2005
Company Name : Motherson Automotive Technologies and
Engineering.
Company Profile : Manufacturing of automotive parts for the Hyundai, Maruti, General Motors, Ford, Nissan and Renault.

Assistant Manager- Maintenance and Process
2002 to 2004
Company Name : Laxmi Electronics Molds and Precision
engineering Pvt. Ltd.
Company Profile : precision mold makers as well as contract manufacturers of Domestic care products for Godrej Saralee, contractors (electric parts) for Schneider Electric and camera parts for Kodak

Field Sales & Service Engineer
1999 to 2002
Company Name : ENGEL
Company Profile : Manufactures the entire range of very high quality injection-molding machines.

Job Profile :
Entire Techno-commercial activities of unit, viz., production planning, quality, raw material sourcing,
inventory control, purchase, dispatch, logistics, safety etc.
Conduct Daily Morning Stand-up meetings at shop floor (with operators) and an inter department office Quick meet (Minutes recorded) to review & achieve quick resolution of daily issues.
Conduct Technical interview process, interview applicants, appoint and conduct technical training of both Operator level and Engineer level on machineries molds and process.
Prepare Budgets, Finalize material & labour requirements according to production goals. With minimal assistance of CAs prepare and analyse trial balance on monthly basis.
Coordinate with Marketing & Production Heads & make wkly / monthly production plan.
Compile reports and calculate operational costs, profit and loss and other overheads.
Analyse process interruptions and streamline flow. Increased average Molding Machine OEE by 2% by
improving process speed to optimum level in 11 machines.
Ensure no wastage of raw material and execute proper shift-closing / handover to the successive shift engineer with clear reporting on accepted and rejected production outputs tallied with issued raw
material.
Ensure max availability of machinery in coordination with Engineering team through periodic preventive and predictive maintenance.(condition monitoring)
Establishing robust process by implementing error proofing (Poka-Yoke) in semi-automatic operation
areas where human interference introduces errors.(Level switch in fluid reservoirs before welding)
Develop new preform sizes and closures with view of revolutionizing costing in mind to stay ahead of
competition. Introduced alternate neck-systems (both preform and closure) with full technical support
to customer blowers, achieved a revolutionary decrease in customer price by 10% yet achieved increase in profitability by 10%. Such products remain as cash cows in company’s product mix for a longer period.
Technical support to customers for blowing, design of new bottles, newer preforms, neck conversion
and cycle time optimizations
Ensure no accident
Monitor attendance and ensure minimum absenteeism for max productivity.
Motivating employees through on the job Training programs and target based incentives on shop floor
to gain full support of direct labour is my key strength.

Key Achievements Summary:
New Projects Implementation : Technology Transfer
eg. Radiator wheel : Technology transfer from Spain for Behr in Chennai & Pune.
Tooth brush Line : P&G, won order of 250 million toothbrushes per year against China.
Expert in Uninstallation, re installation, Machine movement, Layout and Repositioning for
productivity, work flow and Line balancing advantages. Factory set up right from lay out and
utilities planned and commissioned:

23 m/cs- Laxmi Electronics, 71 m/cs- Hindustan Syringes & Medical Devices and 60 m/csMotherson Automotive Technologies and Engineering (MATE).
Approving SLD (Single Line Drawings) from Electrical contractors, Water flow piping and cooling
tower pumps selection, Chiller sizing, air flow and Drier choice for raw material etc.
(MATE, Previous company and Current company)

Pioneered the design & development and Championed the Light weighting of pesticides and Agro
chemical of Agrochemical PET bottles (less weight, high strength) by adapting cost-saving neck
change (by 40%)

Savings of INR 20 million and bagged a State Govt Tender for Annual supply.
By way of simple low capital investment measures of proper dust collection, uniform blending and
right preheating of regrind section, notably improved quality of preforms.

Increased 10% new customers in the low cost market.
Reduced mold breakdown as well as mold change time via SMED, plug standardization of ejector/corepull electrical wiring and cooling connection standardization.

Precisely saved 100 hours in 190 mold changes on 16 machines per month.
Conducted Equipment condition monitoring (Red Tag campaign), made a model machine and.
subsequently executed its horizontal deployment on all molding machinery and successfully
regained rated machine speed.

Improved OEE by 4% in a period of 40 weeks.
Implemented energy saving measures on equipments to remain in standard Specific Energy
Consumption norm (kwH/kg) of PET Preform molding.

Achieved reduction of 6% in units consumed per month just in rising auxiliary equipments to
the rated performance by condition monitoring.

Introduced Load-cell based Day-silo management both in material stores as well as dispatch stores
thereby gaining twin-benefits of precise raw material consumption data online and avoided
customer complaints of less net-weight in boxes.
Introduced innovative ways of recording data in the Raw material mixing section and generated
precise reports on Daily formulation from unskilled labour on the stock and consumption levels of
HP, CP, filler, masterbatch consumptions. Sometimes task remains simple but unexecutable, a
small idea takes to execute it!

Reduction of wastage to a level of 3 tons per month (1%)
Developed an integrated robot arm solution in horizontal machines in collaboration with Wetec,
Taiwan and L&T. Turnkey solution selling concept in L&T PET machinery and Successfully sold more than 200 machines in the segment in a very short period all over India.

Promoted to Head – Application in PET preform Making Machines in 6 months in L & T Plastics Machinery Ltd.

Plastic Trainings Undergone (Overseas)
Schneider, Plastics Processing, Velocity Control Techniques @France
Engel, Advanced Machine Maintenance @Austria
Kodak, Mold Maintenance and Hot Runner Controller @Eastman

Specialist: Plastics Injection Molding
Updated on New Projects & product lines
Expertise in Project Management
Project’s Techno-commercial Viability
Extensive exposure to business CAPEX valuation, machinery selection, plant layout, erection and commissioning of machinery, Design of electrification, piping, utilities selection etc.
Machine and mold qualification
Capacity planning of Machines
Costing of Products and Services
Scheduling & execution of Preventive & Breakdown maintenance of all machinery and utilities.
Error Proofing (Poka-Yoke) & Automation
Hands on experience in processing a Wide variety of plastics materials, expert in PET, PP, ABS,
PA and PC in Product applications such as Automobile, Molded Furniture like Chairs,
Packaging & Process Troubleshooting. Sound knowledge in PET preforms and bottles processing
and closures.
Ability to set up and trouble shoot entire molding process in Injection molding machines viz., Ferromatic, Windsor, Toshiba (former L&T), ISBM –ASB & AOKI, ASV -PM Series, Sumitomo, Demag, Wittmann-Battenfeld right from Tool setup to accepted product molding.
Solve critical processing problems in specialty resin moldings through systematic approach: DOE
(Design of Experiment), VCT Decoupled molding (Velocity Control Technology).
Assessing machine capability through Condition monitoring study. Recording MTTR and MTBF through proper Breakdown History and ensuring proper down time recording with reasons solved in RCA methodology.

Personal Skills Summary
A resourceful Executive Director with an overall experience of 20+ years in Plastics Injection
Moulding, in reputed companies, which includes 15+ years of Project Management experience in Senior Managerial positions in various PET preform and bottle manufacturing projects as well as heading operations of PET preform factories of medium scale.
A champion in managing complex multiple capital projects at multiple locations from conception to qualification - directly related to the manufacturing of PET preforms and rigid containers with overall responsibility for productivity, timing and budget.
An expert in factory Layout, Machinery selection, erection and commissioning of machineries and
utilities, experienced in Planning & Implementation of several Green Field Projects from “Concept
to Production” who can review plant infrastructure, layout and equipment against project requirements, Develop and manage for ugrades and expansion requirements.
A Technical Director who can review new products from a manufacturing perspective, conduct
Techno commercial feasibility studies and prepare market survey reports, do elaborate product
costing, machinery and utility selection as per products, Budgeting Operations, Initiate and focus on continuous improvements in manufacturing and a very successful Technical Trainer in all aspects of
Plastics Injection molding.

A hardcore professional of Production engineering, Lean manufacturing and GMP, who has gained
deep insights by working hands-on, in all departments of manufacturing along his career – be it Production scheduling, Preventive and Breakdown Maintenance, Machine testing and performance
evaluation, Process troubleshooting, Budgeting or Costing, for a duration right enough to spontaneously involve, quickly spot and analyse flaws in any function, resolve the flaws by
generating simple, practical yet sustainable solutions by way of collaborating resources,
channelizing inputs by moving the team forward to maximize productivity and OEE through reduced
rejections, setup time reductions through SMED, recording, analyzing and implementing energy
saving measures, plant automation and optimizing man-power utilization.
A results driven, self-motivated Team player possessing excellent people management skills,
communication skills and superior interpersonal skills, who believes in participative leadership and
is capable of motivating staff to peak performance and consistently produce sustainable results with
a cool-headed approach and loves to handle challenging multiple complex issues that generally
others dare to handle or resolve.
Future Goals
Growth

 

 

     

 

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