Ref. No. : CA - 15500 - (Production - Blow Moulding – with 11.8 years in Plastic Industry)

Education

B.E in Production
DPT( Diploma in plastics technology)
12th
10th

Skill Sets

Computer Proficiency
Operating System:    Windows Xp, Win7, Win 8
Ms Office:  Ms Word, Ms Excel, Ms Power Point,outlook
Others:  Internet,mailing & Computer Fundamental

Core Competencies:-
Production Management
Project Management
New product development
Training & Skill Development
Planning & Vendor Management
Environmental, Safety & Security Management
Total Quality Management

Work Experience

Operation Manager
From - June 2022 to Present
Company profile - Manufacture Glass Containers, Bottles

Job profile -
Daily monitoring of Machine Utilization, Plant efficiency, Performance & OEE improvement of each and every section and making plan to control Breakdown Hrs. & Rejections after doing RCA and why- why analysis.
Check Reconciliation of RM, SM, PM, WIP at production stage and tally with other dept. (as per process routing from store issue to store receive) and doing gap Analysis on wastage and making control plan to avoid it.
Check, Prepare and presentation of MIS of all plant level activity & process to managements and presenting CRM reports and reviews of customers to the managements in every MRM meeting.
Daily monitoring of running projects of developments like Mould developments, Products developments, tools & Machine developments in Plan Vs Actual mode of each & Every Activity.
Responsible to reach the company’s KPI goals (OEE, Customer complaint, Rejection rate, OTIF and PMS as per RACI).
Monitoring & Controlling all PPC activity as per process routing with Dept. owners to set actual requirements of resources to meet expected production plan in minimum cost and within time limit.
Drive root-cause analysis and improvement proposals of all quality related issue- internal as well as external with all respective dept. and with all responsible & accountable person and handover them Kaizen activity as a task with time limit to complete it.
Technically oversee and support validations of New Products, Molds, Machine, Tools & Utility with proper URS and FAT and making sure the installation and commissioning should be done as per SOP and Manual works instructions.
Attending & Provide training sessions on Monthly Production Reports, IQA NCs, Gap of Individuals & Depts., Customer Complains, Monthly KAIZEN & Problem-solving methods.
Lead and execute Lean methods & 5S projects on existing production lines and train workforce to follow the same to increase productivity and reduce overall Down time.
Monitoring and make sure that Preventive & Service maintenance plan of Machine, Mould, Tools & Utility done on time and any abnormality reported on immediate.

Plant Head & Operation Manager
From Jan 2019 to June 2022
Company profile- leading businesses in the Plastic Bottle Manufacturers. Also known for Plastic Bottle Manufacturers,

Job profile-
Daily monitoring of Machine Utilization, efficiency, Performance & OEE improvement.
Reconciliation of RM, SM, PM, WIP at production stage and tally with other dept.
Preparation and presentation of MIS, BOM and CRM.
Introduction of new products development and controlled growth of the production capacity.
Responsible to reach the company’s KPI goals (OEE, customer complaint, scrap rate, etc.).
Coordinate machine and set-up planning to meet production plan.
Lead the daily activities of the production, process engineers and technicians.
Drive root-cause analysis and improvement proposals.
Technically oversee and support validations of new products/ molds, Cycle time, Rejection analysis and make SOP for moldings and Packaging stage.
Coordinate sourcing of molds and their implementation in production.
Be responsible for the corrective & preventive maintenance of molds and machines.
Advise in the development of new products based on plastic components.
Support installation and start-up of new Injection molding & Blow moldings lines.
Create continuous improvement proposal to increase productivity, quality and availability.
Report periodically OEE (KPI) results and improvement actions to Production team and also provide training for improvements.
Set-up and control production using a control plan and SPC.
Lead and execute Lean & 5S projects for existing production lines.
Coordinate validation of mold, equipment and product changes.
Oversee quality assurance according to ISO 9001.
Machine & plant Capacity calculation.
Prepetition and follow-up of Preventive and predictive maintenance plan of mold & machine.
Preparation of developing part trail plan.
Attend FRM, SRM, PRM and production Meeting on daily basis.
Leader of various improvement projects like TPS and internal QCC.
Preparation and follow-up of mold, gauge and measuring equipment calibration plan.
Co-ordinate to HR and store for Man power and Material shortage.
Attend various customers and third-party Audits.
Responsible for all ISO/TS-16949, ISO-14001, ISO-15378 and ISO-27001 documentation.
Active participation in root cause analysis of morning meeting concerns.
Immediate concern on Quality related issues.
Preparation of technical and on-job Training plan and execution of the same to the operator and subordinates.

Sr. Production Executive
From July-2016 to Jan-2019
MOLDTEK PACKAGING Ltd

Job profile-
Process optimization and Process improvement plan for running product, machine, molds and utility.
Defect Analysis and improvement through 7 QC tools.
Implementation of Corrective and Preventive action, Technical Improvement plan and Root cause analysis at shop floor.
Plan for reducing Downtime, controlling Rejection, controlling Breakdown and Increases productivity.
Making record of all Production related documents and Production Reports.
Man power planning and Manpower Roaster (Ensuring that all production areas have skilled operators for efficient machine operation).
Responsible for making Job description, Communication matrix, Competency matrix and skill matrix for Production Engineer, Supervisors, Operators and Helper.
Attend every day PRM, SRM & FRM meeting.
Analyze production process for identification and removal of non-value adding process.
On job training to operators and Production Engineer.
Responsible for system development related work.
Monitoring of process capability & implement and review control charts.
Monitoring of IML & IMD process setting and control the rejection rate in IML production as per given target.
Attend meeting for New product development and for process optimization.
Follow-up of preventive and predictive maintenance of mold and machine in shop floor.

Sr. Production Engineer (Injection Molding):-
From July- 2014 to July- 2016 in
MOLDTEK PACKAGING Ltd.
Job profile:-
All documentation of shift.
Shift handling and manpower setup.
Scrap recycling & waste elimination.
Handling of Injection Molding M/c up to 660 Tonnage.
Injection Molding Parameter setting & Trouble shooting.
Maintenance of Molds, Machine and utility.
Freezing Of cycle time.
Control on Rejection & Downtime by keeping machine and molds and auxiliary equipment’s always in good working condition.
Handling of 50+ workers in a shift.
Material Handling PP, PE, POM, PET, NYLON, PS, PC, ABS, SAN, ELASTOMER etc.

System management:
Certified EMS 14001:2004 & AITF 16949:2016 Internal Auditor.
7QC Tools for problems solving & Kaizen.
Just in time calculation & Productivity Reconciliation.
Vendor Management and Qualification process.
Knowledge of Control plan, SPC, Process flow control.
Zero defect analysis.

Major achievement :
IML rejection reduced in most running products for Castrol and Gulf oil from 30kg/ton to 9.5 kg/ton.
Excellent process setting knowledge on machine like Victor, Zomar, CMP, Lixin, Jagmohan, Milacron, L&T, Toshiba, Fanuc, Arburg, JSW, Prinkan Akar from 100 to 650 ton for avoiding minor stoppage and save 3 to 4 hours per day breakdowns.
In house Hot runner & Cold runner mold maintenance for avoiding delays in customer scheduled.
In IBM Process (Core rod & Cavity) mold polish is done in house to reduced rejection rate and stoppages.

Expertise in Root cause analysis, CAPA, Why- Why analysis, Machine handling (injection molding up to 660T), IBM (UPTO 90 TON), Production Planning, Machine maintenance Plan, Machine performance, Machine utilization, Man Power handling, Painting process on plastics, Rejection Analysis and assurance timely delivery of quality material to next customer .Trial for new development as per customer requirement & improved quality & improved efficiency of critical Machine. An effective communicator with excellent relationship management skills and strong analytical, problem solving & organizational abilities
Reduced mold change time from 45 to 30 mints by modification in storage of mold & other accessories.
Reduced lumps formation form 400kg to 250 kg per month In PP & PE material.

Project work in CIPET:
Worked on film & pipe testing project in CIPET LUCKNOW and CAPS PIPE INDUSTRIES.
Completed training work in HELVOET PLASTICS TECHNOLOGIES PUNE in automobile industry parts.

Objective:
Result oriented visionary executive with expertise in managing diverse range of activities such as evaluation, managing top line & bottom line, process & equipment selection, capacity planning, implementation of project, production, process control, cost management and quality assurance.
Adroit in spearheading the entire of plant activities for the set up standards with accountability for strategic utilization & deployment of resources to achieve organizational objectives including maximizing plant profits & minimizing expenses.
Proficient in managing erection & commissioning of injection moulding plants; expert in managing plant operations including maximizing plant profits & minimizing expenses.
Acquired strong exposure of latest manufacturing methods; skilled in conceptualizing and effecting process initiatives to enhance efficiency and productivity.
An effective communicator and team leader with skills in crisis management, Team building and trouble shooting.

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