• Gender: Male
• Age: 52
• Designation: Manager
• Highest Education Level: Post Graduate Diploma
• Preferred Country: India
• Preferred Location: Anywhere
• Work Experience: 30.7 Year(s)

Education

MBA - Marketing, IGNOU (Indira Gandhi National Open University), 2003.
MS - Manufacturing Management, Birla Institute of Technology & Science, 2001.
Diploma - Management, Ignou, 1999.
BE - Mechanical, Bharathidasan University, 1994.

Skill Sets

Production Planning & Quality

Work Experience

Plant Manager
Since April 2007
Presently working with leading company at Wada, Maharashtra ,
Job Profile
Laminate & Plastic tubing operations management:
Manage the laminate/plastic tubing plant operations, and ensure the key performance indicators are maintained.
Managed the entire operations covering Production, Quality, Maintenance, Engineering, Supply Chain, Planning, Stores & Warehouse, Human Resource functions with a targeted improvement in P&L.
Seek guidance of the Regional Manufacturing Head in meeting the productivity, quality, and yield and delivery targets and achieve profitability.
Identify and initiate quality, process and productivity improvement projects through six sigma, kaizen, TPM, and Lean manufacturing.
Introduce VSM in the Plastic line and reduce lead time, inventory and streamline process flow.
Enhance process and manpower productivity through lean manufacturing and improve efficiency.
Ensure quality, environmental/ food safety and HACCP standard requirements are complied with maintain good house keeping & hygiene in the plant.
Control / monitor of Raw and packing material consumption and wastage.
Product/ process development:
Develop new products and establish effective quality assurance system, food safety programme.
Interact with machinery/ film /adhesives and coating resin/ chemical suppliers and keep abreast of the latest trends in packaging / process technology.
Bench mark towards improving the product quality and serviceability to world class performance.
Human resource development:
Guide and motivate an operations team of 336, comprising of engineers and technicians, review their performance on a regular basis.
Ensure professional development and welfare of the staff, Develop team spirit amongst them.

Major Achievements:
Through enhanced process and manpower productivity, efficiency and reduced lead time improved customer satisfaction.
Increased laminate tube production capacity to 40 million a month & Plastic tube to 6 million and met the customer quality standards.
Successfully transformed the company productivity and quality, with all new & inexperienced fresh EWYL scheme people in manufacturing
Introduced quality systems and stream lined the NPD systems in Plastic tube line.

Plant Manager
Dec 2005 to March 2007
Worked with Swanley Kent, United Kingdom
Job Profile
Performance improvement: Deputed to the Swanley Kent to turnaround companys financial position, improve the operational excellence and to establish systems, Managed the entire operations covering Production, Quality, Maintenance, Engineering, Supply Chain, Planning, Stores & Warehouse, Human Resource functions with a targeted improvement in P&L.
Improved the quality and plant productivity.
Ensured on-time deliveries of right quality materials to customers.
Streamlined manufacturing system and created procedures and established product quality standards.
Introduced daily management review meetings and improved the plant performance.
Product/ process development, cost reduction, energy conservation initiatives:
Increased the space utilization by using VSM, Kanban
Implemented six sigma projects for product quality improvement and reduced power cost.
Optimized logistics and reduced transportation cost by implementing JIT
Reduced inventory levels and reduced working capital requirement.
Motivated Kaizen teams to solve process problems
Implemented Clean room in the entire factory to meet Japanese standards, without affecting the customer deliveries.
Implemented preventive maintenance and condition monitoring system and procedures.
Human resource development:
Established training module for the new recruits.
Motivated the multi-cultural staff of 60 and generated a team spirit with all working for a common goal.
Enhanced employee performance through motivation and appraisal system based on Key Performance Indicators (KPI).

Major Achievements:
Turned around the operations from loss making to profit making in last 8 months.
Improved customer service level from 50% to 90%.
Improved the productivity of the plant by 30% in both printing and tubing sections.
Created additional space in the warehouse by improving the layout.
Implemented lean manufacturing and reduced the cost of manufacturing by 10%.
Reduced cost of spares by 10%
Reduced tool change time 50% through Work study.


Plant Manager
Aug 2004 to Dec 2005
Worked with Essel Propack Ltd, Murbad Mumbai,
Job Profile
As Plant Manager, led the operations team representing Production, Quality, Maintenance, Engineering, Supply Chain, Stores & Warehouse, Human Resources and 110 key personnel and ensured the productivity and profitability targets are met.
Plan, provide material, motivate production team achieve monthly production.
Identified and utilized various techniques and executed process/quality improvement/cost reduction projects, Improved the process capability of critical processes.
Introduced FIFO and stores identification system and controlled inventory.
Implemented clean room project.
Devised and established Preventive maintenance programme for moulds and process plant.
Complied with quality, environmental/ food safety and HACCP standards, maintained good house keeping & hygiene.
Ensured strict compliance to quality norms and controlled the quality.
Developed products as per the market demand.
Guided trained, and motivated the 110 subordinates.
Major Achievements:
Improved the productivity of Injection moulding unit from 120 K per day to 270K per day and moulding and tubing plants by 60% & 20% respectively.
Through Six sigma techniques reduced the quality defects to less than 5000 PPM.
Implemented PDCA & SDCA cycles for continuous improvement.
Introduced 5S concept and improved the GMP of the plant
Reduced cost of spares by 10%

Assistant Manager Production
July 2003 to July 2004
Worked Otis Elevators India Ltd, Bangalore
Job Profile
Managed the operations covering of Amada CNC turret machine, bending machines, Welding shop, Powder coating line & Assembly shop.
Handled production planning, quality and maintenance.
Utilized productivity improvement technique of VSM/ value engineering and enhanced productivity, on time deliveries and reduced lead time/wastages.
Reviewed performance of operators on monthly basis for their performance improvement.
Monitored and controlled critical inventory and improved process productivity.
Implemented ACE metrics and ISO 9001 Quality Management System.
Developed, guided trained, and motivated a competent shift operations team of 32.

Major Achievements:
Through VSM implementation eliminated wastage, improved productivity by 45%, reduced lead time by 35%, reduced storage space requirement for finished goods, raw materials by 43%.
Reduced wastage and scrap through better utilization and value engineering.
Reduced defects by RRCA & Mistake proofing.
Reviewed, monitored and reduced raw material usage (RMU) by 20.

Superintendent
Feb 1998 to June 2003
Worked with TVS Motor Co. Limited, Mysore
Job Profile
Managed 7 process lines and handled production, quality, maintenance, weld shop and printing plant.
Coordinated TPM & TQC activities, SAP implementation for PP module & routine maintenance in the system
As member of productivity, improvement team introduced rabbit chase, forest cell, cycle time reduction in machine shop.
As a Leader of an implementation team, established 3R inventory management system in entire plant.
Introduced the concept of Re-engineering, two-welder in welding
Designed jigs & fixtures for painting and welding.
Achieved, Big Island formation in welding shop.
Managed a team of 150, comprising of engineers and technicians.

Major Achievements:
Improved productivity by 60%
Brought down rejection level from 20% to 5%.
Introduced new system of painting, reduced paint consumption by 40% and saved cost of 8.4 Million INR.

Engineer Product Development
Aug 1995 to Feb 1998
Worked with Hydraulics Limited, Chennai
Job Profile
Developed new products as per customer requirements both in plant and at vendor site.
Coordinated technical activities of ISO 9001.
Established quality control procedures, fault identification and resolution.
Developed jigs & fixtures. Developed products for Hindustan Motors, TVS, Wheels India, and Enfield & LML.
Coordinated production and problem solving activities for Pond cherry plant.

Trainee Engineer,
August 1994 to August 1995
Worked Unity Forging Ltd., M M Nagar
Job profile
Assisted the shop floor engineers in their activities.
Studied and acquired knowledge of production technology and operations.
Understood the systems and basics of manufacturing/ assembly line.

Future Goals

Sr. Manager