Ref. No. : CA -
27096 (Production - Moulding with 17.9 years in Plastic Industry)
Highest Education Level
Masters - Degree
Current Gross Salary
INR 1080000 /Annum
MBA From IASE Rajsthan, IASE Deemed University in 2011 with 72%
PG Diploma From IIP Delhi, IIP Mumbai in 2011 with 60%
PG Diploma From CIPET, Lucknow, in 1999 with 70%
B.Sc. From Magadh University, Bodh Gaya, Chemistry Honors in 1996.
Experience in Plastic product manufacturing plant operations, Packaging Development, Vendor Development & People Management functions with educational background of Post Graduate Diploma in Plastic processing technology, Packaging technology & MBA Mkt.
The wealth of expertise comes from working across plastic Injection molding & Blow molding, Sheet Metal parts & Its Assembly in Electronic Consumer, Automotive & Rigid Packaging products.
I am adept in all facets of production operations, production planning, team building, cost optimization and quality improvement coupled with profound training and development skills.
Familiar with costing knowledge plastic, rubber, Sheet Metal parts & Tools.
Hand on experience of Operational / Capital expense budget control & use ERP (PP Module- SAP/RAMCO).
Having exposure to work in environment having ISO9001/EHS ISO 14001/OHSAS 18001 and IATF 16949:2016, Lean Manufacturing, TPM, KANBAN, Six Sigma DMAIC, DOE, 5’S tools etc.
Work Experience Details
HOD / D.Manager Part Production
Since Jan 2017
Company Profile: Leading global manufacturer for automotive product and leading supplier to all most all OEMs.
Productivity Improvement by 10% - 30% by cycle time reduction @ In-house and Supplier and save > 1000 Machine Hours through Process Improvement / Mould Improvement (Auto De-gating, Sprue Bush Modification) / Robotics / Advance Hi-Speed Machine/ Raw Material & Additives.
Yield Improvement from 67% to 78% @ target 80% through Reduction in sprue runner length, Hot Sprue bush, Hot Runner System & also merging low weight product with higher weight product of same RM.
Man Power Reduction through Development of 4 in 1 module in Molding Shop Floor through Automation viz Robot / Sprue Picker / Sprue Separator Conveyor & Mold modification (Auto Degating)
Shop Floor Lay out Modification for Single Line Flow of child Parts that minimize material movement & Developed Supper Market Model of child Parts.
HOD / Manager Production
Nov 2015 to Dec 2016
Company Profile : Leading manufacturer of Interior and exterior Automotive lighting for Four Wheeler OEMs.
Successfully completed project of Porsche 14 mm thick light guide SIL & Qualify JLRQ.
Productivity improvement by 15% & Warpage control within ± 0.5 mm of 14 mm thick light guide of Volvo SIL Lens & Reflector through development of Cooling fixture
Yield Improvement by 10% in 04 Mould by Hot Sprue bush.
OEE improvement from 76% to 84.2% & Man Power cost reduction by 1040 Man Hour / month
Consumable item consumption reduction by 5%.
Mould maintenance cost reduction by 10%
Nov 2013 to Oct 2015
Company Name : Ecorea & Kuroda Electric India Pvt. Ltd
Company Profile: Is an ISO 9001/TS 16949 Korean + Japanese MNC organization Its core business is manufacturing of – Injection molded automotive & electronic consumer white good plastic products for Automotive OEMs viz. Nissan, Toyota, Yazaki & Electronic Consumer goods OEMs. – Viz. LG, Sharp, Brandenburg, Jabil etc.
Job Profile :
Improve In house Rejection from 6% to 2.5% through continuous improvement activity viz. startup rejection reduction by improving process repeatability, restructure team, developing fixture to simplify work, standardize work process etc. & Succeeded in reducing assembly idle percentage from 1.6% to 0.9% through LOB & streamlined component flow.
Coordinate in installation and commissioning of 03 Injection molding machine under plant expansion project and conduct new and existing mold trials for customer.
Productivity Improved by 8% through process optimization & robot optimization, breakdown reduction.
Reduced overall facility downtime by 10 % by improvement project on Mold change over time reduction, Machine setup time reduction and reduction break down time due to spare and tools.
Cost saving projects through Manpower saving, Electric Power saving, Raw material saving etc.
Implement close loop system to utilize maximum reuse of material consumption with product quality constraints.
Improve product handling rejection through introduction of product based packaging Trolley & PP Box.
Restructured department man force for better Productivity, Rejection control, Co-ordination between shift, communication and also for man power saving and cost saving.
Assistant Manager-Engineering & Development (Plastic Products & Packaging/Palletizing): Apr 2010 to Sept 2013
Assistant Manager-Injection Molding & Packaging/ Palletizing: Apr 2008 to Apr 2010
Senior Engineer -Injection Molding & Packaging/ Palletizing: Apr 2004 to Apr 2008
Engineer-Injection Molding & Packaging Palletizing: Nov 2001 to Apr 2004
Company Name : Moser Baer India Ltd.
Company Profile : Manufacturer of Storage Media (CD-R, DVD-R), Solid state media (Pen Drive), Photovoltaic Solar Panels, LED lighting, Solar lantern lighting having state of the art manufacturing molding plant.
Job Profile :
Restructured In-house existing resource for Plastic Junction box & LED light molding projects, Developed & procurement of moulds & machine with payback & requirement analysis, Raw material selection & development, Conduct FAT and established process for smooth production with project tracking & monitoring.
Reduced cycle time for productivity enhancement (15%) without compromising on quality and started continuous improvement activity through regular monitoring of cycle times and raw material consumption, down time analysis and reduction.
Played a pivotal role in development of packaging like - Rigid injection molded plastic cases / boxes. Different types of printed corrugated master cartoon / product display Trays / Duplex paper Soft boxes. BOPS/PVC/BOPP shrink wrapping film / LDPE monolayer stretch wrapping film / LLDPE cast film. Wooden pallet, Palletization, container stuffing (as tertiary packaging) as per legal & customer.
Cost saving projects DMAIC methodology (Six Sigma) – through raw material saving through consumption reduction by reducing weight & Low cost alternate material utilization, Master batch consumption reduction.
Achieved more than 90% compliances in departmental BSC / FSC (Balance/Functional score card).
Improved vendor rating from 74% to 91% within 1 year by training & development.
Zero injuries & lost time (2009) safety audit report.
Improved customer service metrics (CRDD) by 8%.
Utilized packaging setup for the dispatch of Retail & bulk pack to DTA & export customer.
Awarded Best Employee award (2007) & Best appreciation KAIZEN awards (2005).
Achieved success in implementing TPM on shop floor as team member.
Trainee to Shift Engineer
Sept 1999 to Oct 2001
Company Name : MAG Filter & Equipment Pvt Ltd
Company Profile : Manufacturer of Automotive filter, Logo, other exterior and interior Injection moldings components for Four Wheeler OEMs.
Manufacturing Operation / Production Planning & Control / Quality Assurance / People Management:-
Steer part production manufacturing operation and directly managing / responsible for output of a team of Assistant managers (max. 02), Supervisors & Engineers (Max. 08) overseeing (max. 90+) exempt and non-exempt employees in 3 shift production operation.
Direct management of work centre PQCDSM, Development & Implementation of DWM & KPIs of direct reportee.
Established & Manage all daily operation viz. Capacity planning, Daily production plan, production schedule, Staffing & Labour requirement, Material control, Supply chain, availability of required resource (4M), Manufacturing BEST practices viz. Kaizen / Quality circle etc., Process optimization, quality control, continuous improvement, employee training & development, employee grievances & providing timely resolutions on the same.
Inventory management through Kanban / JIT (Just in Time) methodology for CRDD metrics & Inventory cost reduction.
Development of the strategic framework for Manufacturing and led the team in delivering on productivity improvement of 10% annually, Visual management system for tracking performance against goals and highlighting problem areas for improvement, Increase Direct Labour efficiency, Yield Improvement, Energy saving, Man power saving.
Ensure composite reports viz. OEE, Gap analysis, CAPA/QPR, Inventory on daily basis to track and adjust productivity in order to exceed weekly, monthly, and yearly plans, carrying out analysis rendering solution and technical support to the team to reduced wastage and time loss.
Proactively assist Plant management in a manner that ensures the reduction in the component cost, develops the vendor base, meet agreed monthly compliance. Attain monthly Indent meeting to finalize monthly plan / Off Loading of tool / Machine / Tool Maintenance schedule, responsible for daily production meeting & Management review meeting.
P&L responsibility of plastic moulding & sheet metal stamping product & Identification of Key matrices to derive continuous improvement plan and to manage & operational and capital expense budgets.
Planning and effectuating predictive and preventive maintenance for the machines, moulds and equipments. Coordinated longer term planning for major maintenance projects. Developed spare part management for tools and prepared plans & budget for reconditioning / new tools to minimize MTTR & MTBF.
Assured / Audit compliance with quality and process specifications & Establish operational policies and implement process improvements to ensure superior quality and outstanding output. Ensure system, procedures & documentation for shop floor operations in line with ISO/TS16949/EHS 14001 standards. Representation of production in APQP/ PPAP activity.
Ensure customer specific trial for developing moulding process & engineering samples for qualification, Solution of customer issue, Coordination with marketing, Purchase, Supply Chain & Vendors for smooth flow of business operations.
Established an employee capability matrix, Planned and conducted training of employees in customer service skills, technical skills, and safety policies and procedures, new safety initiatives, problem solving 8D to develop staff, facilitate efficiency to improve performance, grow positive morale environment, increase responsiveness, decrease costs of quality, ensure that a safe workplace.
Engineering / Process Excellence :-
Researched and purchased injection moulding machine & its ancillaries and mould, raise Capex, justify purchase with, ROI, Making standard for machine equipment purchase, Cavity Optimization of tools, Process variation reduction, Shift Layer Audit.
Plan and execute Plant equipment rearrangement for streamlined process flow / Shop floor layout optimization without production loss and Introduction, Coordination, management and evaluation of the installation of new equipment and processes in area of responsibility to minimize customer costs and improve margins, Automation project in molding, Cost Reduction through Zidoka.
Mould Flow & Design Review, Cavity Utilizations & Process Engineering, RM selection, Mold procurement, trial & validation, BOM, CAPEX, ROI & ensuring smooth flow of material through optimized work place layout. updating latest Technologies
Established and employed LSS methods (Lean manufacturing & Six Sigma) & carrying out time & method study, Man / Machine efficiency study to measure and maintain productivity and quality improvement processes, wastage reduction viz. cycle time reduction, scrap reduction, set up and change over time reduction, Ensure the process capability of various machines and effectuating various energy saving programs.
Supervising / Coordinating entire product development such as requirement analysis, finalizing specifications, design review, prototype development & testing activities and off-tool parts development.
Quality circle formulation on shop floor for eliminating wastages while enhancing plant efficiency and productivity.
Vendor Development / Supplier Improvement :-
Researched vendors, Identifying and transitioning work to outsourced vendor, reduction in total manufacturing costs, developing long-term partnerships & Rendering technical assistance to supplier for product / tool development. Assessing performance of the vendors. Auditing the vendor for technical up gradation, quality management system and achieving long term cost cut projects @ Plastic Injection Molded parts, Rubber Parts & Blow molded parts.
Packaging Technology :-
Manufacturing of Packaging product – Rigid Injection / Blow molded plastic packaging product qualification & trials, manufacturing, conducting detailed tests to evaluate quality & finalizing BOMs, MSS & updating database accordingly, review & upgrade packaging quality specification for better performance
Matching, developing packaging according to standard design & specification based on customer or market inputs. Working on various cost optimization projects in Packaging through modification in primary & Bulk Packaging materials.
Hand On experience :
Horizontal as we as Vertical Injection molding machine from 2000T to 10T (All Electric & Hydraulic system) of different make for Thermoplastic / Thermoset Plastic, Extrusion Blow molding machine up to 20 Ltr. Capacity Sheet Metal machine from 20T to 45T.
Post Molding Operation - Ultrasonic/Vibration Welding, Annealing, Buffing.
Auxiliary Equipment –
YUSIN & YUDO 2 axis / 3-6 axis Robot.
L&T motan material feeding system, Scrape Regrind Granulator & Annealing Chamber.
Different types of Hot runner controller
Water Chillier / MTC / Hot & cool system etc.
Processing of different Plastic raw material as well Sheet Metal Material (0.2 gm to 4 Kg)–
Thermoplastic PC, PC Glass filled, PC + ABS Alloy, PBT, GPPS, HIPS, SAN, ABS, PMM, POM, PPCP, PP-Glass filled, PP- Talk Filled, PPHP, HDPE, LDPE, EVA,PVC, PPE+PA (Xyron), Nylon6, Nylon66, Nylon Glass Filled 7% - 50%.
Injection molding Grade Phenol compound Thermoset.
Sheet Metal Low carbon steel, CRCA, Copper, Brass etc.
Product Range Exposure -
Automotive 2 Wheeler Switches and Handle Bar switches & 4 Wheeler Interior and exterior lighting Assemblies & Body Trim, Air Filter Assembly, Ducts & Tanks, Electrical Relay base body, lower/ Side Cover, 2 Wheelers Helmet & Other Accessories.
Electronic Consumer LCD Back cover & Front cover, AC Inlet Grill, Font Grill, Fan, Washing Machine Tub Outer, Tub Cover, Control panel, Refrigerator Veg. Tray, Water tank, Multi duct, Door End cap etc
Junction Box for PV Cell Module i.e. Casing, Cover, Fixing Part, Connector body male / female, Sleeve connector, Nut, Solar Lantern, LED Bulb & Tube Housing.LED Bulb,
Packaging Products Jewel Box, Slim case, Cake Box, DVD Box, Thermoformed boxes / Trays, PP Box, CC box, CC Lid / Corner for palletization & Wooden Pallets.
Trial, Qualification, Process setup of different types of moulds - Hot runner, Hot runner with cold tip, 2/3 Plate mould, Multi cavity Cold runner mould.
Training / Certification
Professional Training Accounting and Taxation from TAAP Pune 2015.
Training in TPM, Six Sigma Yellow belt, ERP Production/Inventory module – RAMCO/ SAP,
Train the trainer (2 day training) at MBIL etc
Production planning & Control
Plastic Processing & Packaging Technology
Plastic Injection & Blow moulding
Plastic tool development & Review
Sheet Metal stamping
Engineering & Process Excellence
Supply chain coordination
Standards & Procedure development
Cost Control / Optimization
Training and Development
Achievement-driven professional Seeking Senior Manager Assignments in Manufacturing Organization..