Ref. No. : CA - 11866 - (Production - Moulding – with 27.8 years in Plastic Industry)

Education

Post Graduate Diploma in (Plastic Processing Technology) from Central Institute of Plastics Engineering and Technology, Lucknow in 1996.

B.Sc. (Physics, Chemistry & Maths) from VSSD College, Kanpur, Kanpur University, in 1994.
Higher Secondary from BNSD Inter College Kanpur, U.P. Board in 1990.

Matriculation from Ramlala Higher Secondary School, Kanpur, U.P. Board in 1988.

Skill Sets

Cross-cultural experience in Injection Moulding/Extrusion Production, Maintenance, Mass Manufacturing, Large Scale Manpower Handling, PPC, Quality Assurance, System & Process, Team Building.

Injection Moulding Production (2500 Ton, 1800 T, 1300T, 850T, 650T, 550T, 450T, 350T, 280T, 250T, 180 150T).
Engineering Plastics Processing.
Plastic parts for Casings of data storage products, Medical devices & Washing machine parts.
High Speed & High tonnage Injection Moulding process & Mass Manufacturing.
Extrusion of reprocess plastic material, Raw Material Sourcing & Reuse.
Maintenance of Moulding Machine, Hot Runner Mould, Chillers and accessories.
Spare Parts development, Indigenization and Inventory Control.
Injection Moulding New project Setup and Operation.
New Advance Tool Room setup and operation.
Large Scale Manpower Handling (56 Roll + 125UST) & Operational Safety Compliance.
Cost Reduction by using Green Belt Project approach.

Work Experience

Production Manager
Since Oct 2018
Job Profile :
Preparing Monthly operation plan for production & Machine capacity utilization based on Monthly sales/Business plan for moulding.
Prepare daily machine loading plan on the basis of requirements.
Daily and Monthly MIS review.
Annual budget review.
Preparing cost saving & improvement plan and executing them timely.
Managing end to end production operations of 41 Injection moulding machines (Thermoplastics) (275 ton to 80 tonnage) for FMCG Products.
Processing of plastic material PP, ABS, Hips, HDPE, LLDPE.
Preventive & breakdown maintenance of machines, mould, & other equipment’s.
Managing Cutter Section to regrind rejection for use.
Controlling Scrap generation.
Managing purchase team for raw material , spares follow up.
Coordination with customers (Dabur, Bajaj, Nestle, Perfetti) regarding supply and quality problems.
Maintaining 5 s and floor management on daily basis.

Production Manager
May 2018 to Sep 2018
Company Profile : Home appliances & auto mobiles Products.
Job Profile :
Preparing Monthly operation plan for production & Machine capacity utilisation based on Monthly sales/Business plan for moulding.
Prepare daily machine loading plan on the basis of requirements.
Daily and Monthly MIS review.
Annual budget review.
Preparing cost saving & improvement plan and executing them timely.
Managing end to end production operations of 17 Injection moulding machines (Thermoplastics) (1800 ton to 80 tonnage) for Home appliances products, washing machine, Refrigerator, and coolers & Car interior.
Processing of plastic material PP, ABS, Hips, Nylon, PC+ABS etc.
Preventive & breakdown maintenance of machines, mould, & other equipment’s.
Managing Cutter Section to regrind rejection for use.
Controlling Scrap generation.
Managing purchase team for raw material, spares follow up.
Coordination with customers (LG, Honda, Orient, Havel’s, Symphony, TSSR, Amber, New Holland &Escorts.) regarding supply and quality problems.
Maintaining 5 s and floor management on daily basis.

Production Manager
Nov 2015 to Mar 2018
Company Name : Noble Moulds’ pvt. Ltd
Company Profile : Home appliances Products.
Job Profile :
Preparing Monthly operation plan for production & Machine capacity utilisation based on Monthly sales/Business plan for moulding.
Prepare daily machine loading plan on the basis of requirements.
Daily and Monthly MIS review.
Annual budget review.
Preparing cost saving & improvement plan and executing them timely.
Managing end to end production operations of 37 Injection moulding machines (Thermoplastics) (1800 ton to 80 tonnage) for Home appliances products, washing machine, Refrigerator, Ahuja speakers and coolers.
Processing of plastic material PP, ABS, Hips.
Preventive & breakdown maintenance of machines, mould, & other equipment’s.
Managing Cutter Section to regrind rejection for use.
Controlling Scrap generation.
Managing purchase team for raw material, spares follow up.
Coordination with customers(LG, SAMSUNG, AHUJA, VOLTAS, USHA, HINDWARE, INTEX, MICROMAX ETC) regarding supply and quality problems.
Maintaining 5 s and floor management on daily basis.

Production Manager
Aug 2014 to Feb 2015
Company Name : Injecto plast Pvt. Ltd
Job Profile :
Preparing Monthly operation plan for production & Machine capacity utilisation based on Monthly sales/Business plan for both moulding & extrusion lines.
Monthly MIS review.
Annual budget review.
Preparing cost saving & improvement plan and executing them timely.
Managing end to end production operations of 21 Injection moulding machines (Thermoplastics + Thermosets)- (90 to 650 tonnage) for automotive parts(Engine & car interior).
Managing assembly line production which incorporates ultrasonic welding, vibration welding, Pad printing with poke yoke system.
Managing finishing of Thermo sets brake system parts after production which incorporates Baking & measuring of components.
Dealing with OEM for product & process qualification and customer complaints.
Processing of plastic material PP, ABS, NYLON, PBT, POLYACETAL & PLENCO Thermo set material.
Preventive & breakdown maintenance of machines, mould, & other equipment’s.
Managing Cutter Section to regrind rejection for use.
Controlling Scrap generation.
Managing purchase team for raw material , spares follow up.
Co-ordinating with new product development team for OEM & EXPORTS.
Co-ordinating with accounts & logistic team.

AGM - Operations
Apr 2013 to June 2014
Company Name : ALP Plastics Pvt. Ltd.
Job Profile :
Preparing Monthly operation plan for production & Machine capacity utilization based on Monthly sales/Business plan for both moulding & extrusion lines.
Monthly MIS review.
Annual budget review.
Preparing cost saving & improvement plan and executing them timely.
Managing end to end production operations of 14 Injection moulding machines (30 to 450 tonnage) for automotive parts.
Managing 04 extrusion lines production (weather strip, roof ditch, glass run channel etc.) & its secondary operation equipped with power press, moulding, heat joining, 3D bending & cutting machines.
Dealing with OEM for product & process qualification and customer complaints.
Processing of plastic material PP, ABS, PVC, TPO & TPE.
Preventive & breakdown maintenance of machines, mould, & other equipment’s.
Managing tool room equipped with advance machines like wire cut, lathe, milling & grinder etc.
Managing PVC compounding & Cutter Section to regrind rejection for use.
Controlling Scrap generation.
Managing purchase team for raw material , spares follow up.
Co-ordinating with new product development team for OEM & EXPORTS.
Co-ordinating with accounts & logistic team.

Manager - Production
Mar 2012 to Mar 2013
Company Name : Polymedicure India Ltd.
Job Profile :
Managing the production of injection moulded article for Medical devices on 80 Ton, 120T, 150T, 180T, 280T & 350T machines. (Total – 54 Machines)
Processing of plastic material PP, PC, PVC, ABS, Plyacetal and HIPS material.
Production of reprocess plastic material by extrusion plant.
Preventive & breakdown maintenance of hot & cold runner moulds. (150 moulds)
Managing In-house Tool Room facility for spare parts development mould maintenance & modifications.

Asst. Manager (Injection Moulding + Tool room) –
Oct 2007 to Mar 2012
Sr Engineer- Injection Moulding: Oct 2001 to Oct 2007
Engineer - Injection Moulding: Jan 1999 to Sep 2001
Asst Engineer - Injection Moulding: Aug 1996 to Dec 1999
Company Name : Moser Baer India Ltd
Job Profile :
Injection Moulding
Handling high speed close loop Injection moulding machines (150 to 280 Ton) to operate at 4.7 second cycle time with 8 cavity hot runner mould. (Total – 64 Machines)
Processing of plastic material PP, PC, ABS, HIPS, polyacetal and GPPS material.
Extrusion of reprocess plastic material, Raw Material Sourcing & Reuse.
New moulds trial and its validation.
Maintenance of accessories like chillers, hopper dryer and material loader are meeting the high-tech process requirements.
Managing Automatic bundling process.
QA Lab equipped with testing equipment and gauges like MFI Tester, Tensile Tester, Warpage gauge etc.
Automated material feeding and mixing system.
High Speed Horizontal and vertical product take out robots

Tool Room
Preventive & Breakdown maintenance of multi cavity hot runner moulds.
Managing In house Tool Room facility for spare parts development mould maintenance. (125 Moulds)
Spare Parts development, Indigenization and Inventory Control.
Planning of Tool Room Machines like Lathe, milling, grinder, EDM & CNC.
Strengthening vendor source and developing alternate source of suppliers; responsible for development and inspection of Spare parts, estimation, costing and finalization of quotations.
Finalizing purchase orders schedules and follow up with vendors for supply of spare parts.
Designing technical training modules & delivering training on different topics like conventional & CNC machine operation.

During above Chronicle
Production:-
Preparing Monthly operation plan for production & Machine capacity utilisation based on Monthly sales/Business plan.
Monthly ‘MIS’ review.
Managing end to end production operations and meeting dispatch target on day to day base.
Determining future needs of production capacity for producing required quantities of items on pre-defined standards.
Preparing weekly & daily production plans with a view to ensure timely accomplishment of production.
Sustaining quality standard with cost reduction attempts by using validation process & end use application.
Continuous Improvement in product and process by using KAIZEN approach.
Creating a facilitating & safe work environment by using 5S Technique & Customized 5S programme “SATRANGI”
Controlling Rejection & Scrap for cost effective production.
Ensuring adherence to customer wise quality standards and maintaining documents.

Maintenance:-
Preventive and Breakdown maintenance of Injection Moulding m/c, Assembly line, Auxiliary Equipment’s.
Preventive and Breakdown maintenance of multi cavity Hot Runner mould.
Managing Inhouse Tool Room facility for spare parts development, Indigenization and inventory control.

Manpower:-
Manpower deployment of 56 Roll Employee & 125 UST.
Individuals employees performance tracking and performance appraisal of all roll employees
Dealing with IR issues, grievances handling and counselling.

Manpower recruitment
Training and Development:-
Imparting continuous on job and classroom training for defect control, wastage control and customer satisfaction under manufacturing reliability programme.
Imparting continuous classroom training for Operational safety of Employees and machinery under EHS.
Designing technical training modules & delivering training on different topics like conventional & CNC machine operation.

Achievements
Machine selection, Installation, Commissioning and its production of JSW make high speed close loop injection moulding machine at Moser Baer India Limited.
Eliminated post assembly operation by mould modification. This has resulted in annualized cost saving of Rs.60 Lac and reduced assembly line operation.
Wastage elimination in Plastic raw material by recycling. Annualized cost saving is ~ 3.0 Crore.
Consumable cost reduction by 15%.. Annualized cost saving is 10.0 Lac.
In house development of core, cavity & mould parts this has stopped import from Japan. Annualized cost saving ~ 2.5 Crore. Received Best employee of the month.
Received Multiple time Appreciation from management as “ON THE SPOT AWARD” for :-
Usage of low grade & recycle plastic material and reducing cycle time of injection moulding machine by Mould modification.
Best EHS, 5S department & Generating storage capacity at salvaging cost.
Motivating employees by giving highest Kaizen’s from department for continuous improvement and assessing records of all actions.
Additional responsibility As a “Tool Room process specialist for JB/CB/MFD & New product.
I received LONG SERVICE AWARD for completing 5 year and 10 year of service.
Established ISO 9001:2000 System in Moser Baer India Limited. (Floppy Division)
(Mould efficiency Improvement):- Mould efficiency improvement from 77% to 93 % by studying process, correcting moulds and providing solution to the existing challenges in system. – Polymedicure India Ltd.
Converted 06 Cold Runner moulds into Hot runner mould to eliminate Runner & Sprue wastage & to reduce Cycle Time. – Poly Medicare India Ltd.
Injection moulding plant set up in ‘ALP’ for automotive products.
Developed substitute raw material resources for extrusion line production.
Arranged New Hot Runner Tips of 03 Hot runner mould on FOC BY Husky In Manjushree of cost 8 lacs.

Project
Green Belt Project :-
Project :- Reducing Slim case weight from 42gm to 36gm
Annualized Cost Saving : 1 Crore
Project Tenure :- 1 year
Year :- 2009-2010

Project :- Mirrors (cd / dvd cavities) refurbishing at Local level – 40 cavities/Months
Annualized Cost Saving :- 2 Crore
Project Tenure :- 1 year
Year :- 2010-2011

Trainings
Internal Quality Auditor by ERTL, Govt. of India in 2000.
System Awareness Training for ISO: 9001:2001 in the year 2003 (1 Day)
Six Sigma Yellow Belt by Moser Baer in 2006.
Planning and Problem Solving (1 Day)
Processing of engineering plastics material at Application Development Centre, Gurgaon at G.E. Plastics 2006 (1 Day).
Communication skills and Development 2007. (2 Days)
Training by External Faculty on 5S, SPC, Poke-Yoke, DOE, and FMEA in 2006. (2 Days)
Managerial skill (1 Day)
Train The Trainer by WCH Training Solutions in 2008.
5S, Kaizen, FMEA, Staying Ahead, Behavioural Skills, Autonomous Maintenance, Fire Fighting, Presentation & Communication Skills & First Aid by Moser Baer.
Perfect planning and flawless execution by Insignia Solutions Pvt. Ltd. (2011).
Achieving & winning with people by Mr. Anil Bhatnagar.

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