• Gender: Male
• Age: 55
• Designation: Manager
• Highest Education Level: Diploma
• Preferred Country: India
• Notice Period: 30  Days
• Work Experience: 32 Year(s)

Education

Post Diploma in Plastics Mould Design (PD-PMD) From Central Institute of Plastics Engineering & Technology (CIPET) Bhopal, in 1994

Diploma in Mechanical Engineering (DME) From Board of Technical Education, Chandigarh in 1991

Associate Membership examination of Institution of Industrial Engineers (India) From IIIE, Bombay Prelim section Completed. Section A appeared

Skill Sets

Project Management, Plant Operations, Production Engineering, Tool Engineering, Injection Moulding Quality Assurance, Process Excellence, Vendor Development, People Management

Work Experience

Factory Manager
Since Feb 2015
Company Profile: Manufacturer Of Pens, Chair, Table, Plastic Products
Job Profile:
Responsible for overall plant operations. T
Steering complete plant operations independently in the capacity of DGM- Plant Head.
Plant includes injection Moulding Section, conventional tool room, Utilities, assembly and Conveyorized packaging lines, Refill extrusion lines, refill manufacturing (ball pens/Gel Pens) and printing lines .
My reporting is to Group CMOO (Chief Manufacturing Operations Officer)
Total strength of plant is 1000+ including on roll/ contract workers and staff. injection moulding shop floor primarily deals in processing of multi cavity imported moulds of various pen parts made of Engineering plastics e.g. SAN, PC, ABS, DELRIN , PS & TPEs. All moulding machines are equipped with auxiliary equipments such as hopper dryer, dehumidifiers, MTCs and on- line hydraulic oil filtration machines. plant printing section is comprising of Indian/Chinese mix of Hi speed pad printing machines.
Plant is doing direct invoicing across India as per sales orders received thro ERP system. Company has tied up with good no. of logistics chains/transport companies having strong base (region wise). Raw material warehouse and FG storage being managed within the plant premises by competitive stores/procurement team. all commercial transaction being carried out thro smart ERP system which is centrally connected with HO - Mumbai/Daman warehouse for maintaining stocks ledger. As a Factory Manager ensuring all statutory compliances through plant HR/Third party legal support agency

Addl. GM – Works (Plant Head) 
Dec 2010 to Jan 2015
Company Profile : Manufacturing Writing Instruments 
Job Profile : 
Steering entire plant operations in the capacity of Addl.GM – Works (Plant Head) and reporting to Sr. VP Manufacturing based out of Delhi. The plant sub section includes Injection moulding shop floor comprising of L&T closed loop machines (24 nos.) , SPM assembly Machines with automatic PLC control (78 nos. approx). Conventional tool room with EDM and cylindrical grinder, Mould maintenance capable of making new Mould/inserts parts developments along with routine moulds maintenance, Machines maintenance and Utilities section. Also am a core team member of tooling design feasibility study & submitting recommendations to management for getting necessary approvals of importing new injection moulds as per business/new product requirements.   
Heading a team size of 625+ members (inclusive of permanent and contractual work force- 580 nos. approx.) from all the sections .Total 30 Staff Team members wherein 12 direct reportees from the level of Asst. Manager to Senior Manager.
Preparing and presenting annual manufacturing budgets/Capex to Group President  in consultation with Sr. VP-Manufacturing.
Review of product pricing WRT overheads transferred in (OTI) on monthly basis.
Implementing automation projects in order to reduce head counts and subsequent productivity improvement.

Senior Manager – Operations - Moulding Production Section.
Oct 2001 to Dec 2010  
Company Name : Moser Baer India Limited
Company Profile : A professionally managed, one of the largest producers of Storage Media (CD-R, DVD-R) in world having state of the art manufacturing moulding plant with an investments of over Rs. 2000 crores doing business globally with few of fortune 500 companies too, It has entered in new business arm in photovoltaic cells/ modules with an investment of 1000 crores and set up the state of the art plant in the same premises.
Job Profile : 
Steering entire manufacturing operations as Senior Manager –Operations including production (injection moulded components), process improvement through automation, materials management and mould modification activities.
Liaising with external vendors for mould development & supply of plastic components in CD packagings.
Proactively assist the Sr. GM -Manufacturing in a manner that ensures the reduction in the component cost, develop the vendor base, ensure availability of plastic packaging components on production lines to meet agreed monthly compliance.
Establishing system and procedures for shop floor operations in line with ISO –9002/OHSAS/18001/EHS 14001 standards.
Managing day-to-day activities of suppliers – Problem solving, technical support, negotiations, relationship with supplier executives, etc.
Developing moulding process and preparing engineering samples for qualification and review.
Attainments:
Significantly reduced the downtime of Mould/Moulding Machine and proposing continuous improvement activities through regular monitoring of cycle times and raw material consumption.
Successfully proposed & implemented continuous improvement activities through changing Moulding Process for Cycle times and Raw Material Consumption.
Developed alternative machines at low cost with improved productivity. 
At Printing & Packaging:
Steering entire productivity and operational functions in printing and packaging department for 
6 Kammann Printing Machines.
6 different pack type packaging machines e.g. video box, bundle wrap, over wrap cake box packing, Aqua Mini JC bundle wrap and bulk on spindle packaging machines.
Maintaining close coordination with maintenance team to improve various processes.
Handling On line label packaging on bundle wrap products along with special type of round stickers development with purchase team
Optimizing processes by changing in-house process of IJL from Kammann to Hanky print machines after study of UV curing system of competitor.
Handling special printing products such as Ink Jet printable export orders on camera machines.
Heading a team of 150 members from both the sections including 10 direct reportees from the level of Asst Manager to Deputy Managers.

Attainments:
Successfully executed 
Lean Six Sigma Green Belt Project on “On Line Cake Box Packaging” as Leader from Motorola.
Scrap Reduction Project on plastic parts (jewel cases/discs – CDRs/DVDRs).
Taking initiative to save energy cost in operation areas e.g. clean room AHU loads reduction/ moulding heat load reduction thro insulation jacket on barrel
Proposed system of on line packaging rejection thro ERP which would control by MRP thro back flush feed back and accordingly indent qty for running SKUs could be maintained

Assistant Manager – Materials & Vendor Development, Exports Division
Oct 1995 to Sep 2001
Company Name : Luxor – Parker 
Company Profile : A world-wide well known group of companies manufacturing writing instruments and shaving products for Indian and Overseas Markets.
Job Profile : 
Administering complete material and vendor management functions in the company.
Identifying and developing vendors for various engineering operations as per business requirements.
Conducting mould trial (local/imported) on various injection moulding machines such as Cincinnati Milacron, Windsor, etc. at vendor location.
Undertaking heat treatment study for various parts of tool.
Modifying existing tools/components as per requirement.
Developing tools for plastic and sheet metal components.
Heat treatment study for various parts of tool.
Selecting plastic raw material & mould/tool material as per product requirement.
Optimising the production line and control quality to minimize the rejection rate.
Maintaining coordination with assembly dept. & technical support to mould maintenance department.
Providing technical support to purchase & material control department.
Attainments:
Instrumental in maintaining high quality standards & executing various activities in compliance to the assigned guidelines (SPC, One point Standard and Quality Feature Standard).
Successfully optimized Moulding Process Parameters for new product development.

Engineer Design & Vendor Development
Nov 1994 to Sep 1995
Company Name : Fore Front Electronics Private limited 
Company Profile : It is electronic industry mainly dealing with electronics calculators & toys, clock movement, gears for watches & allied electronics products
Job Profile : 
Developing overall production & machine scheduling activities and coordinating with supervisors to meet daily production requirements.
Conducting trial and design assessment of new development.
Identifying and developing vendors for cost effective procurement of:
Mould Bases.
Plastic Raw Material.
Sheet Metal Parts.
Moulding Job Work.
Designing and developing injection moulds (2/3 Plate) and conducting moulds trials at vendor location.
Developing moulding process and preparing engineering samples for qualification and review.
Guiding tool room persons in various machine operations (S.P.M./Conventional) for development & maintenance of moulds.
Continuously interacting with vendors regarding quality complaints & other production related problems.
Attainments:
Defined and established machine parameters for higher productivity and optimal performance on Machines like Windsor, Engel and Mafatlal-Niigata from 100 to 300 tonnes.

Production Engineer
1992 to 1993
Company Name : SR Forgings

Trainings/Seminars Attended
BASF Styrenics Pvt. Ltd., Bharuch, Gujarat for process study of GPPS/ HIPS Polymer.
JSW Ltd.: Hiroshima Plant, Japan for basic training of all electric injection moulding machines.
Fuji Seiki Ltd.: Matsuyama /Nara Plant Japan to know technology manufacturing of high speed Multi cavity hot runner moulds.
Jaewoo Moulds precision (JMP - Korea) for new product launch, mould manufacturing and trials.
YUDO – Korea for hot runner study.
World Best Co., Korea to study robot manufacturing processes at project level.
JMP, Korea for multi cavity CB moulds developments.
TDK, Luxembourg for Injection Moulding plant feasibility study before purchase of machines.

Trainings/Seminars Attended
TPM (JIPM) – Confederation of Indian Industry (CII).
Pneumatics/ Electro Pneumatics parts of IMM – SMC Pneumatics.
Compressed green belt module programme (Six sigma) – Motorola.
VSM (Value Stream Mapping) – CII.
Seminar on Plastics Manufacturing Technology – Reliance Industries Ltd.
CAD /CAM Workshop – HOPE Technologies.
ERP Production/Inventory module – RAMCO.

Core Competencies
Project Management: 
Responsible for managing overall project related activities (from deciding the layout to meeting customer specifications & interaction and technology transfer across the Globe.
Leading project conceptualization, basic engineering, detailed engineering, estimation, planning & implementation of project plans within preset budgets and deadlines. 
Planning for optimizing man & machine utilization, reducing wastes for enhancing productivity. 
Manufacturing Engineering
Overseeing production related tasks including planning, control and troubleshooting of plastic moulding  material and IT hardware products.
Handling capacity enhancement and cost reduction initiatives and ensuring escalation of plant productivity.
Introducing process controls and consumption norms to avoid process wastages. 
Implementing project plans within deadlines and defining best practices for project support & execution.
Preparing engineering samples from Moulding process side and involved in Resource Allocation & Utilization and conducted requisite Training Programmes Supervising production activity and achieving minimum rejection through rejection analysis on daily basis. 
Overseeing production operations entailing product development activities as per changing market needs, vendor management, as well as handling industrial relations. 
Conducting regular inspection and tests to ensure the process capability of various machines and effectuating various energy conservation programs.
Vendor/Supplier Development: 
Developing long-term partnerships with suppliers, managing supplies performance of vendors to ensure meeting of service, cost, delivery and quality norms. 
Consistently evaluating vendor performance to ensure adherence to predefined specifications and supply of quality material/hygiene/execution of job works.
Rendering technical assistance to vendors for product/tool development.
New Product Development
Studying the system and package based on the surrounding components for development of new products.
Coordinating the entire product development activities including requirement analysis, planning, finalizing specifications and prototype and off-tool parts development.
Suggesting new ideas; preparing project plans and technical specifications for smooth execution of projects within the time and cost parameters.
Dealing with suppliers for managing quality/
quantity of incoming material and implementing strict quality measures to ensure quality of the materials/ equipments and reducing rejection level to minimum. 
Troubleshooting all technical problems; ensuring that the work executed are in compliance with the pre-set quality specifications. Troubleshooting fixtures, tools & machines.

Process Engineering/Quality Assurance
Identifying assignable and chronic causes by the use of latest analysis techniques for eliminating wastages while enhancing plant efficiency and productivity.
Working towards cycle time reduction, scrap reduction, set up and change over time reduction, process flow improvements as well as throughput time reduction.
Ensuring adherence to quality standards & maintaining all related records and documents.
Monitoring the quality of products during the entire production process.

Notable Attainments – segregate as per company
Played a pivotal role in reducing cycle time for productivity enhancement without compromising on quality.
Initiated many cost reduction activities by modification in manufacturing process, using Alternate Material, challenging the consumption norms, setting new targets, and setting new consumption norms.
Instrumental in Master Production schedule in coordination with Raw Material Planning, Machine Scheduling, Parameter Setting and Calibrating for meeting Productivity Capacity Requirements

Snapshot
Career spans nearly 23 years of experience in Manufacturing Operations, Design & Tool Engineering Operations, Procurement and Vendor Development, Process Improvement and People Management.
The wealth of expertise comes from working across Plastic Moulding and Electronic industry.
Currently working as DGM-Plant Head ; dealing in Injection Moulded Products, Assembly processes on SPM Chinese assembly machines, mould maintenance , tool room, refill manufacturing, extrusion, hot transfer filming and pad printing processes.
Proven abilities to enhance the production process operations; optimize resource & capacity utilization, escalate productivity & operational efficiencies; while curtailing costs & expenses across organizations. 
Possessing sound knowledge of Plastic Technology, adept in updating latest Technologies and instrumental in proposing solutions to optimize Production in compliance with the Quality Procedures.
Adept in Design & Development of New Product, moulding Design Review, Cavity Utilizations & Process Engineering activities, ensuring smooth flow of material through optimized work place layout.
Skilled in Assembly Related Work, Plastic Injection Moulding Process, Product Design and development, Six Sigma, PDCA, Kaizen, TPM, DMAIC, DOE & 5S.
Familiar with costing knowledge for plastic components/tools to be developed.                   
Deft at carrying out time study, method study, worker output study, machine/man efficiency study, process improvement, etc. Possess exceptional work ethics, routinely use available time to solve problems; ability in multi-tasking and timely completion of all assignments.  
Hands on experience to use ERP (Production & Inventory Module-RAMCO)/SAP-MM Module.

Future Goals

Growth