Ref. No. : CA - 15734 - (Production - Compounds & Masterbatch – with 18.6 years in Plastic Industry)

Education

PGD in Plastic Processing and Testing (PGD-PPT) from CIPET Lucknow (U.P.) in Jan 2005 with 70%

B.Sc. (PCM) from Dr. B. R. Ambedkar University Agra in 2003 with first division

Intermediate (PCM) with first division from UP Board in 1999.

High school from UP Board in 1997 with first division 

Skill Sets

Computer Proficiency:
SAP (PP Module), MS office, Internet & Keyboard kills.
To be a contributing member in an organization, this belongs to Engineering Polymer technology family in technical, production manufacturing area with strong acumen of knowledge and hardworking.

Work Experience

Sr. Production Engineer
Since June 2009
Company Profile: A leading manufacturer of Nylon PA6 & PA66, PBT & PE Glass filled & unreinforced materials
Job Profile:
Core Competences:-
Safety:
Troubleshooting, Rectifying and implementing effective techniques to avoid near miss (Accident) in plant.
Ensure High Safety during Working and House-Keeping in the process plant area as per SHE standards. 
Creating a positive and developing Climate, with respect to S.H.E.  Ensure that site meets an SHE Standards and Directives. Ensure completion of all relevant statutory documentation related to S.H.E in line with Local Laws.
Quality:
Knowledge of Quality Tools, Control Plan, FMEA, PFD, 5S Implementation, Job Safety Analysis (J.S.A), Standard Operating Procedures (S.O.P), Machine Safety Analysis (M.S.A), Lock Out, Tag Out & Try Out (L.O.T.O.T.O) and RCA.     
Job Profile
Safety and Housekeeping:-
Develop and monitor the relevant safety and environment protection policies and procedures according to corporate, company and SHE requirements, applied in the relevant areas together with site SHE manager and Operations Leader.
To maintain clean and safe working environment that supports production activities.
Concern for safety, health & Environment and strict enforcement of safety norms (LOTOTO, Safety Work Permit and LSR Rules).
Implementation of “5 S” in plant area and surrounding.

Planning of Production activities, budget control, and implementation:-
Plan, Direct, Coordinate and Monitor overall production and related activities within company Policies and Procedure.
Ensure all production activities operated within the agreed budget in a cost effective manner over Capital and operating expenditures and accomplishment of Total manufacturing objectives in time & quality.
Improvement in plant OEE and FTR with reduction of change over time, scrap, rework and breakdowns through Kaizen process, Lean process, 6 sigma process (etc.).
Maintenance notification (MWN) through SAP for reduction of online breakdowns.
Monitor the trial production of new / modified products on main line by working closely with product development team to ensure the production capacity able to cope with the new requirements.
Material issue request and production transfer given to warehouse as per production planning by SAP. 
Material balancing in system with physically production on daily basis.
Responsible for highlight absolute inventory and block inventory.
Responsible for implementation of MOC (Management of Change) in process plant.
Responsible for change and update production SOP’s. Training given to all concern people. 
Responsible for production consumable budget.
Preparation of DPM (Daily Plant Meeting) report, monthly reports for WIP and preparing final production stocks. All the data entry process SAP ASSISTED and reported to operation manager and finance department.

People management:-
Train and develop the production supervisory staff and operators.
Establish and maintain a positive community relationship between management team and down the line staff.
Monitor the performance of down the line staff and assign the job accordingly.
Training and motivation of new incumbents and manpower handling.
Encouraging the people to give suggestions/ ideas for improvement of process, safety etc.
Adequate the shop floor people for safely run the plant.

Quality and Customer Focus:-
Implementing quality systems & Procedures in the organization to ensure smooth flow of operation.
Technical up gradation of the process leading to good quality, high output at low cost and active participation in R & D trials on main lines.
A compliance of ISO and TS system, its documentation and implementation on shop floor.
Ensure implementation of total quality management system on shop floor and educate the people for same.
Ensure implementation of control plan and FMEA.
Responsible for make 8D report of customer complaints with the team and implementation of action plan.
Responsible of on time dispatch of FG material in FGWH.
Responsible for quality of RM which is issued on production floor.

Achievements:-
Achieve lowest scrap % in DSM engineering plastics plants with Implementation of new ideas and IP projects.     
Achieve FTR and yield with in the targets.
Achieve lowest change over time in the DSM engineering plastic plants.
Achieve 99.99% accuracy of WIP inventory.
Every year break monthly highest production record through reduction of                         down time, stabilize process, reduction of COT and proper production
planning by good team work.
Achieve zero SHE incidents (LWC & RWC) during the period in DSM.
Leader of IP project for reduction of manufacturing customer complaint. 
Achieve zero customer complaint.
Get certification of TS, ISO and EMS every year with zero NC.
Developed cleaning procedure to minimize down time between different colours product productions.
Mixing procedure improved to achieve good quality homogeneous product and also record system developed to have records for future production.

Machines Handled:- 
W&P ZSK-70+ Compounder Extruder.
K-Trons feeders & Twin feeder systems.
Tumbling Dryers for SSP process.

Shift Supervisor - Production
Dec 2007 to Jun 2009
Company Profile: A leading manufacturer of engineering thermoplastic filled & Unreinforced materials
Job Profile: 
Achievements
Team member of commissioning of W&P ZSK-52V Compounder Extruder. 
Achieve highest production in a month from 200mt to 500mt by Stabilization of new extruder.
Implementation of data entry and material transfer and issue by on line 
my SAP R/3 PP-Module shift wise.
Training of TS and ISO audit.
Develop safety culture in the shift people. 
Material movement planning and control as per material requirement of grade change.

Machines Handled:- 
W&P ZSK-52V Compounder Extruder.
K-Trons feeders & Twin feeder systems

Assistant Officer - Production
July 2005 to Jan 2007
Company Name: Bhansali Engineering Polymers Ltd
Company Profile: A leading manufacturer of ABS & SAN Polymer and alloys production.
Job Profile:  
Achievements
Handling of 11 extruders from training period. 
Achieve highest per day production from 60mt to 120mt with minimize the manpower.
Implementation and training to my SAP R/3 PP-Module.
Shift wise material balancing of all production with handling of 11 Extruders.
Improved flexibility in operation through Training.
Reuse of scrap & rejected material. 
Reduction of manpower & COT by modifying production process.
Safety and firefighting training. 

Machines Handled:- 
W&P ZSK-70MC & SC (Mega & Super compounder).
W&P ZSK-83V Compounder Extruder.
APV MP2080 Extruder.
Kolsite made Single & Twin screws Extruder.
K-Trons feeders & Twin feeder systems.

Special features: Training got about 
Training of “5S” Implementation.
Kaizen yellow belt for reduction of change over time.
SHE Leadership Course for Operational Managers.
Leadership Training for managers from Dale Carnegie Training Program.
ISO, TS and EMS awareness training. 


Future Goals

A result oriented professional with proven abilities in enhancing the productivity and technical know how of a polymer processing, raw material and machinery. 

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