Ref. No. : CA - 15804 - (Quality - Blow Moulding – with 30.1 years in Plastic Industry)

Education

Master Of Business Administration – Production,from North Maharashtra University,in 1999.

MSC – Physics, North Maharashtra University,in 1993 (Distinction).

BSC–Physics from Poona University in 1991(First Class).

PGD in Computer, North Maharashtra University, 1994. 
PGD in Labour Laws, BAMU University, 2000. 
Certified Lean Six Sigma Black Belt,IIBM, 2010.
 
Certified Lead Auditor for ISO 9001-2008 
Certificate in Project Management Professional and Entrepreneurship Development. 



Skill Sets

roactive decision maker, targeting challenging assignments at senior managerial level with reputed organization
Brings to table over 19 yrs in Lean Six Sigma, lean, TPM,TQM, Production Planning, Cost Reductions, Quality, Plastic moulding products, Collapsible Aluminium Tubes, Aluminium bottles etc and having Certified Lean Six Sigma Black Belt Professional, Certified ISO 9001:2008 lead auditor, Project Management and Entrepreneurship Development training

Work Experience

Deputy General Manager - Quality & Systems 
Dec.14 - Till Date
Company Profile: Worldwide as a manufacturer of aluminium and plastic containers, partnering with pharmaceutical, agro chemical, liquor, cosmetics and various other industries for all kinds of custom solutions of packing.
Job Profile: 
Perfect team manager having ability to lead cross-functional project teams and integrate their efforts to maximize operational efficiency. Proficient in striking perfect coordination with all involved agencies ensuring bottleneck-free work execution with skills in conceptualizing and effecting process initiatives to enhance plant efficiency and productivity. 
Demonstrated abilities in working on initiatives, thereby bringing down equipment breakdown & achieving annual costs savings. Excellence in Process Engineering. Raw material grinding reduction in process.
Well versed with various quality standards such as ISO, TPM, Kaizen, six sigma and lean concepts. Adept in handling process improvements and quality related activities involving resource planning, in-process inspection and co-ordination with internal departments.
Conducted the IKEA, Carrefour, KMART, WALMART Technical & Ethical Social Compliance audits and WALMART CT-PAT audit with 90% rating.
Hands on experience of implementation of 5 –S in factory and various training programs conducted. Packing line efficiency improvement thro innovative ideas based on TPS. Manpower alignment at production and packing lines. 
Excellent communicator with an analytical mind and ability to lead a team under extreme conditions. Deft in maintaining high quality standards with analytical and problem solving skills. 
Training on various fields in quality, Six Sigma, Lean, TPM, cGMP, motivation, communication skills etc.
Management Representative for ISO, ESC, CT-PAT, asset verification, pharma audits, etc.
Key Skills: Six Sigma, Lean, TPM, 5-S, Kaizen, PPC, JIT, Process Improvement, poka yoke, SPC & SQC, QMS lead auditor, Project Management, Line clearance, SOPs, etc

Core Competencies: Strategic Planning ~ Production Planning ~ Quality Control and Manufacturing ~ TPM Implementation Coordinator ~ Team Management ~ Supplier Quality Systems ~ Process Audits ~ Failure Analysis & Investigation ~ New Product Development ~ Vendor Assessment ~ Cross Functional Coordination ~ Training & Development ~ Team Leadership ~ Process Development ~ Relationship Management.

Professional Experience
Executive Highlights
Operations from incoming goods, in process to despatch in close loop to achieve product as per customer requirement. Handling the customer complaint resolution with RCA & CAPA.
Executed projects on improvements in injection moulded machines to get the OEE >85 %, packaging of plastic containers, PET bottles, Blow moulded containers like ice boxes and others. Online packing - concept of PVSM. Delivery time reduction from 30 days to 20-21 days by effective planning and tooling.
Setting up system on the basis of order processing sheet to track the work order wise flow of the components.
Changeover time reduced to 65 min from 240 min for mould change on >450 tonnage and 40-50 min for less than 400 tonnage by identifying the offline and parallel activities.   Cycle time improvement of few moulds till 15%
Material flow management by conveyor system and VSM for material flow from stores till dispatch.
Co-ordination of marketing team with production and dispatches to maximise the sale.
Wastage and rework control at production and packing level.
Successfully executed managed projects: Optical fiber quality Parameter benchmarking to World Class Level. In house Capacity expansion / improvement by innovative methods in current set of equipments and Machine effectiveness improvement as per various Six Sigma tools and Lean concepts.
Instrumental in driving Single Mode Fiber process of two Sections of optical fiber manufacturing nit with the team
Established credibility by efficiently managing Integrated Management System combining all ISO: 9001-2008, OHSAS: 18001-1999, ISO: 14001-2004 certifications. 
Contributed in an IT environment and executed: Auto Production Report ? Masters Control Program for Consumables, Spares, GRR, Linearity ? Auto Mails to All for Production Reports, Salary, and Deviation in Process ? Entry Modules for Production/Security/HR/Safety and report generation.
Exercised WIP control through ERP and decision making. Paperless area by Process Log Book Elimination and all records in ERP through Automation Programs
Decrease in Scrap by optimising the process and changing the hardware by innovative methods and kaizen techniques and sustained the yields.
Third party audits like ESC, ISO, CT-PAT, etc clearance within close loop environment.
Awards & Accolades:
?"CEO Performance Award”, 2006 – 2007
?“Award of Excellence”2005 – 2006
?“Award of Excellence”, 2006 – 2007
? Award from Management for CT-PAT audit clearance with 91 % compliance
Process Engineering
Applying the principles of mass, momentum and heat transfer to process and equipment design. Identified the opportunities for Lead Time Reduction & Cycle Time, WIP Reduction and Quality improvements, Overall Grinding reduction from 12 % to 4.3% in Pyramid plastics
Brainstorming with the departmental employees to identify the improvements projects to Reduce Rework, Waste, Second grade and Customer complaints. Managed the cost and time constraints of projects.
Responsibility for risk assessment, necessitating hazard and operability studies, for the health and safety of both company staff and the wider community.
Liaising with other process engineers, working on associated plants. Preparing reports, flow diagrams and charts for employee awareness to current improvements / waste or second grade reduction.
Reviewing existing data to see if more research and information need to be collated and assessing the adequacy of the existing processes and equipment.
Lacquering process optimization in collapsible aluminium tubes for improved quality
Quality Control and Manufacturing excellence
Identifying areas of quality failures and taking steps to rectify in system through process check and audits. Driving the Continual Improvement Program in line with the organization’s strategic vision
Executing Six Sigma and Lean Tools for: 
Control Charts and Engineering Process Control
Stratification, Multivariate Analysis, Differential Diagnosis 
Pareto analysis and waste / rework reduction, Process capability analysis using SPC and SQC, 
Failure Mode and Effects Analysis, COPQ, DMAIC cycle , SIPOC Model , SMED , 
Design of Experiments (DOE) , Evolutionary Operations (EVOP) and DFSS 
Inferential Analysis, Multiple regressions, MSA, Calibration 
VSM for Process Flow chart / Material movement to Check Muda activities and removal of same 
Involved in Poka-Yoke For Mistake Proofing, Single Piece Flow, Takt time
JIT, MOST Concept Implementation, Kaizen Culture
TPM Implementation Project Diver: Plant wide TPM Activities project driver trained by JIPM-S, 5S / lost cost tree / OEE / OPE / P-M Analysis as start up process and completed pillars of TPM such as ?Autonomous Maintenance (Jishu Hozen) ?Planned Maintenance (Kaikaku Hozen) ?Focused Improvement (Kobetsu Kaizen) ? Early training & education ? Quality improvement ? office TPM ? SHE (Safety, Health & Environment ? 16 types of Losses breakup - 8 - Equipment losses, 5 - Labour effectiveness losses, 3- resource consumption effectiveness

Team Management
Identifying and implementing strategies for building team effectiveness by promoting a spirit of cooperation between team members. Tracking areas and helping for the development of multi skilled work force for cross utilization within sub processes for optimum efficiency.


Deputy General Manager-System & QA
Dec 2011 – Dec 2014,
Company Profile: Leading manufacturer of injection molded and blow molded plastics houseware 
Job Profile: L

Future Goals

Seeking to apply my expert knowledge to the company and reach further ladder of achievement and making the cultural changes as per quality standards.

Copyright © 2003 - 2015 Smartech Global Solutions Ltd. All rights reserved. Designed by Plastemart.com