Ref. No. : CA - 14001 - (Production Planning - Plastic Products and Processing – with 33.5 years in Plastic Industry)

Education

MBA in Operations Management & Packaging Management from National Institute of Planning and Technology, Ahmedabad

Diploma in Chemical Engineering From Bharathi Vidyapith Pune

Lead Auditor ISO-9001 - IRCA UK approved

Skill Sets

Result oriented professional with over 23+ years of qualitative experience across Area of Plant Operations ,Quality, Manufacturing & Quality Management Systems
Out of 23 year experience 14 years experience in PVC film, Printing, Flexible Packaging & PVdC coating
A capable, results orientated Head/VP Operations/Mfg. with experience of leading high performance teams and of successfully increasing efficiency and productivity whilst reducing costs and inefficiencies. Ability to keep a level head at all times, nurture and grow a business, evaluate opportunities and risks and also deliver innovative new solutions to challenges. Possessing excellent client facing and configuration skills and highly successful in helping define company direction

Work Experience

Head Operations & Quality
July 2013 till date
Company Profile: Manufacturer of strip and blister packs that for food and FMCG products
Job Profile:
Develop a strategic plan to advance the company's mission and objectives and to promote revenue, profitability, and growth as an organization.
Oversee company operations to insure production efficiency, quality, service, and cost-effective management of resources
Work closely with the President-Operation on manufacturing plans, goals, and future product innovations
Develop and manage budgeting and budget execution with a focus on product costs and margins
Overall in charge of day to day operations in factory
Responsible for overall direction, control and management of all activities within the manufacturing and logistical operations of the factory
Responsible for formulating policies, programs, and objectives affecting the schedule, quality, and cost of manufactured products
Directing and co-coordinating production according to quality and quantity specifications within cost objectives
Developing manufacturing and operational strategic plans and generally overseeing their implementation to ensure maximum capacity utilization of the manufacturing units towards achieving the group’s strategy, growth and profit objectives
Providing strong leadership to the employees at the plant, ensuring high morale, team work and good employee relations, at all levels
Ensuring all divisions within the manufacturing area are properly staffed and co-ordinate to perform duties effectively
Oversee all operations and logistics of all the plants and maintain financial discipline
Able to meet and subsequently exceed performance targets ensuring profitability of the individual manufacturing units
Supervise and provide technical guidance to subordinates
Responsible for all the technical & commercial matters except finance and marketing
Should ensure daily, weekly & other targets for all departments that are assigned by the management met within time frames
Should ensure proper systems are laid out in all departments and backed up by proper MIS reports (plan Vs Actual)
Responsible for Quality Products by setting up Quality Assurance Department and Quality Management Systems as per FMCG Industry standard
To ensure that employees at various levels are upgraded by organizing Training Program
Overall maintenance of the organization for the best service at all times
Responsible for all Safety aspects of the factory as per Safety standard norms

Vice President - Manufacturing
Mar 2006 to Jun 2013
Company Profile: Manufacturer of high-end pharmaceutical packaging products like Cold Form Blister and Child-Resistant-Blister packaging.
Job Profile:
Achieved ISO: 9001:2000 certification & USFDA Approval within span of 14 months.
Achieved Best Performer of the year 2008-2009 Award.
Achieved exemplary performance & its contribution to the growth of the organization
Award of the Year 2012.
Significant contribution in working on a Green Site Project.
Established the plant & Product with in the span if six months.
Achieved over all recovery from 93% to 96.5%
Achieved wastage % from 6.5% to 3% (PVC film ) & 18% TO 8% (PVDC coated PVC film)
Over all product cost reduction by 7%
Productivity improvement by 15%
Setting up Process & product. Validating process & product.
Setting up the Goals (In line with Objective of the organization) and monitoring its implementation.
Taking up overall control of PVC Calendaring & PVDC Coating plant (operations) Planning, Production,
Quality control & assurance, maintenance, new projects, administrative & HR
Handling Material control & quality management systems, product development & launches (New products
developed Viz.: Metalized PVC film, lacquer coated metalized PVC film, PVDC coated BOPP film)
Setting up the quality system as per pharma requirements & cGMP Guidelines
System as per cGMP guideline established & implemented within span of nine months
Ensuring compliance with applicable statutory requirements, such environmental control, factory's act, like safety etc.
various labour enactments. Quality Systems -ISO 9001 & CGMP requirement as per 21 CFR guidelines

Head-Quality & Management Representative
Apr 2001 to Feb 2006
Company Name: Bilcare Limited - Pharma Packaging Research
Job Profile:
Management Representative of the organization for ISO 9001:2000 (with design).
Integrated ISO system in SAP system.
Key driver for a paperless organization and Steering Committee member for ERP system installation (JD Edwards) and creation of a unique web based Management Information System (MIS).
Chief Representative for critical customer quality audits.
Played a key role in handling the expansion project from design to installation and commissioning.
Initiated Supplier Quality Assessment/Audit/development system.
Looked into the Global Benchmarking for about 115 parameter Bilcare range of products
Successfully reduced the Customer Complaint Management index more than 98%
Implemented SAP for the Quality Assurance department as a key User
Eliminated inspection stages by process and system improvements
Developed on-line process monitoring system
Streamlined all new products for quality parameters
Increased productivity from 150 tons to 270 tons per month by monitoring

Manager-Quality Assurance & Management Representative
Jan 1997 to Mar 2001
Company Name: Swastik Rubber Products Ltd.
Job Profile:
In-charge of Quality Assurance activity of the site at shop-floor levels and led a group of 25 Q.A. inspectors for in process & final product testing.
Spearheaded operations for Supplier Quality Assessment/Audit & New Supplier Development, Self Certification of Supplier, and Customer/Third Party & Government Inspection.
Key Q.A. member for product development & launches.
Have been instrumental in evaluating the need for statistical techniques for evaluation of CP/CPK of products critical in nature & present data to Director operations depending on the risk involved & weakness of the area, machine give copy to the concern departmental heads for corrective & preventive action & improvement.
Reviewed requirements of inspection, measuring & test equipments & any other inspection facilities & present to Director Operation for up gradation/procurement of inspection & test equipments
Controlled further processing of non-conforming products until correction of deficiency
Consistently improved QS 9000 (APQP, FMEA, PPAP, SPC & SQC) implementation

Executive-Quality Assurance & Management Representative
Jun 1994 to Jun 1996
Company Name: Esquire Polymers Ltd.

Assistant Engineer
Feb 1993 to Jun 1994
Company Name: United Technologies Pvt. Ltd.

Trainee
Oct 1991to Jan 1993
Company Name: Mahindra & Mahindra Limited

Have wide knowledge of business processes and their integration throughout the complete business operations.
Effectively planning and executing the projects as per design and user requirements.
Packaging development as per Customer (Pharma & FMCG) requirement.
Understanding of quality parameters and quality systems keeping in mind continuous improvement in the process using various methodologies.
Worked on a green site project and successfully established the plant, Product, ISO system and UDFDA approval within a short span of one year.
Management representative for ISO: 9001 (14 years). (Lead Auditor for ISO 9001)
Skilled at planning & scheduling work, establishing systems, setting goals & standards, identifying & solving problems/ conflicts, making decisions and weighing risks are the strength area.
Strong analytical, problem solving & organizational abilities.
Setting KRA'S & objective in line with Organization VISION and its implementation.

Distinctions:
Designing, Erection & Installation of PVDC Coating plant.
Validating PVDC Coating process & all types of PVDC coated product. Handling PVC Calendaring & PVDC coating plant. ( 110 employees- including works manager, managers & executives)
Establishing Quality System for Zero Customer Complaints.
Productivity, Wastage Monitoring, Recovery improvement and overall manufacturing cost reduction.
Manufacturing activities for critical operations.
Material control, Material reconciliation from raw material to Finished Goods.
Vendor development and Self Certification.
Product development.
Raw Material, Processing and product Cost reduction

Project Management:
Implementation of project from selection of machinery to Commissioning of equipments.
Interpret, evaluate and resolve critical project execution bottlenecks for timely completion of projects without cost overrun. Minimizing performance bottlenecks for high productivity with maximization of men, material & machine utilization.
Stabilizing the products on new line
Commercializing the product by field trials and presentation of product attribute to the potential customers
Ensuring fulfillment of technical and contractual requirement of the project.
Product cost reduction below competitive market price.

Operations Management:
Planning day-to-day strategies of man, material & machine utilization for optimum output, machine utilization (loading) for optimum output.
Actively interacts and coordinates with various departments and organizations for statutory approvals and resolution of local issues.
Executing cost saving techniques/ measures and modifications to achieve substantial reduction in expenditures and work within the budget.
In depth knowledge of Quality Management systems and in implementation techniques.
Identifying assignable and chronic causes by the use of latest analysis techniques for eliminating wastages while enhancing plant efficiency and productivity.
Minimizing performance bottlenecks for high productivity with maximization of men, material & machine; preparing process sheets & estimate sheets for the same.

Quality:
Ensuring adherence to the quality measures outlined.
Establishing quality standards, implementing stringent quality control systems to enhance quality of products and reduce rejection level.
Defining and monitoring Quality policies, projects, regulations and management policies and maintaining the related documents for the same.
Establishing quality standards, implementing stringent quality control systems to enhance quality of products and reduce rejection level through continuous up gradation of ISO systems to observe better compliance in line with changing market/ customer requirement.
Inspection - Incoming
Working in close coordination by providing technical guidance and deployment of quality plan to deliver quality raw materials.
Periodic evaluation of performance in terms of quality, delivery and service and seeking corrective measures in improving the quality of raw materials.
Process Enhancements
Recommend modifications & rectifications in products for quality standards where warranted.
Maintaining Reports and intimating concerned departments in regular time intervals

Consultancy Of ISO 9000 For Following Companies
Hi Tech Printer Ribbon Pvt. Ltd. Pune – ISO 9002
Technocrats India Ltd., Mumbai – ISO 9002
Kayems Equipment Pvt. Ltd., Mumbai – ISO 9001
Kayems Engineering. Pvt. Ltd., Mumbai – ISO 9002.

QMS Audit Faced Experience With Certification Bodies - Kpmg, Dnv & Tuv
Certification Audits: 08
Pre-assessment Audits: 08
ISO 9001 & 14001 Certificate Renewal Audit: 02
Surveillance Audits: 34









Future Goals

Currently looking for senior level assignments in Operations/Manufacturing/Packaging/Quality with an ambitious organization preferably as V.P. /G.M. - Operations/Packaging/Quality.

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