Ref. No. : CA - 7431 - (Production - Extrusion - Woven Sack – with 33 years in Plastic Industry)

Education

MBA In Industrial Management From Adarsh Management Institute Of India, Ahmedabad.
B.Com from Chattisgarh University, Raipur in 1997
Diploma In Mechanical Engineering From Jabalpur Polytechnic ,Securing 63.7% in 1993

Skill Sets

Seeking any suitable challenging assignment in Maintenance / Marketing / Manufacturing in Plastics products like Woven Sacks, LD/HM sheets,water Rolls, shrink film, Shopping bags and carry bags, and other plastic products.

Work Experience

Factory Manager
Since October 2012
Company Profile: Manufacturer and exporter of HDPE/PP Woven Sacks, Fabrics & Multicolor Printed BOPP Laminated Woven Sacks

General Manager
October 2010 - Aug 2012
Company Profile: Leading producer of PP woven sacks, Liners, LD/HM films, water pouch rolls and bags, shopping bag, recycle material.
Job Profile:
To ensure that Production and dispatch are achieved as per schedule
All Plants, machines, utilities are maintained to an optimum level performance
Quality of products is achieved as per customer’s specifications and satisfactions.
All staff and labors are managed efficiently and timely trained them.
To plan and implement the ways to reduced the price of products.
Achievements:
Increased Production: Capacity utilization of Plants, man force, reducing downtime and breakdown by preventative maintenance helps to increase production by 20% within 1st four weak only and reduction of wastage to minimum level i.e. 5%
Wastage & CC: Reprocessed and reused Polymers wastage up to 30% and CC up to 40% in Woven Sacks and 70 % RP with 40% CC in Shopping bags (above 12 micron) without affecting product quality and quantity.
Power Consumption: Power consumption had been reduced from 1.2 units per kg to 0.99 unit per kg by proper utilization of Chillers, compressors and Extruders

Production Manager
October 2008 - Sept. 2010
Jai Corp Ltd
Company Profile: Leading manufacturer of PP/HDPE Woven Sack, Geo Textiles, Geo Membrane, Carpet backing, Ground cover, low GSM flat fabrics, liners and FIBC with 11kva express power supply of sanctioned 2000kva
Job Profile:
Man force requirement: and arrangement: To establish and agree labours and staff requirement with Directors and line managements and arrange skilled man force timely like T/P, lamination, Reprocess, Loom, Printing M/c operators, Mechanic, Electrician etc
PPM: Develop and implement daily, weakly and monthly production planning of different qualities of HDPE/PP tapes, fabrics and sacks as per deliveries schedules and monitor the production and inventory on daily basis.
Efficiency: To ensure that all the machines and equipments are functioning as per machine manufacturer’s specifications and production quality products acceptable to the customers through the process of audits of machines
Performance Appraisal: To develop and implement worker performance appraisal system and develop different incentive scheme to achieve maximum productivity
Machine spares and consumables: To monitor and control the availability of machinery consumables and spares parts stock in line with production requirements of customer demand, projected sales and target stock holding.
Follow-up: Follow up with purchase and store department for spares
Cost and Power control: To maintain daily total factory and department wise power consumption, Man power, spares and other expenses to maintain Cost/kg of the product. To maintain profitability.
Liaison with outer agencies like electricity Board, Vendor development, local Engineering Transporters, banks, spares suppliers and machine suppliers etc
ISO: ISO Documentation of work procedures, preventive maintenance, calibrations as per ISO 9001-2008 rules and formats
Responsibilities for maintenance:
Responsible for breakdown and planned preventive maintenance of electrical / mechanical and electronics installations of all Tape Plant, Lamination, RP plants, looms, Chillers, Compressors, etc
Maintenance and reprogram AC/DC Drives, electrical control circuits etc:
Erection & commissioning of new plants and machines,Transformer and main bus- bar Panel installations, Main cabling, cabling to individual machines and plants, lighting, Earthing pits formation, its inspection & connections, water & air pipe lines, cable tray formation & fittings etc
Maintenance of process control instruments like temperature controllers, level controllers, pressure transducers, Barrels and Die heaters, reprogram of analog and digital drives of ABB, Delta, mitsubshi,lenze, siemens etc
Maintenance of D.G Sets, H.T Transformers, H.T and L.T panels, air circuit breakers, factory lighting, air conditionings, bus bar modification etc
Achievements
Cost reduction upto 20% by the followings:
Increased Production: Capacity utilization of Plants, man force, reducing downtime and breakdown by preventative maintenance helps to increase production by 20% within 1st four months and reduction of wastage to minimum level i.e. 5% in local and 8.5% in GEO
Wastage & CC: Reprocessed and reused Polymers wastage up to 30% and CC up to 40% without affecting product quality and quantity.
Power: Conducted energy audits by daily monitoring power consumption of individual machines proportionate with production, machine proper lubrication, reduced misuse by man power awareness and implemented several other measures to save energy.
Reduced Rejections: Implemented the concept of internal customers between different sections of manufacturing which helps us to maintain product quality resulting rejection is minimize to minimum level

Project / General Manager
July 2005 to Aug 2008
Mozambique Sacks Ltd.
Company profile: A leading producer of injected, mounded and thermoforming plastic goods in Africa.
Key responsibilities:
Custom clearing: Clearing all imported plant and machine from Nigerian Customs department by means of clearing agent.
Building constructions: Arrangement of builders /local massions, Plummbers, electricians and as per our requirements, understand the quantity & quality of material needed negotiate the price and and discuss the matter with Chairman and get approval and procure materials and start construction.
Logistics : Look for the Transporters and other local workers for plant and machine offloading
Laisoning: Laisoning with Electricity boards for 33 KVA supply, water supplier, Bankers, and other government formalities to start production in Africa
Erection and commissioning : Erection & commissioning of plants and machines, transformer and main bus- bar Panel installations, Main cabling, cabling to individual machines and plants, lighting, Earthing pits formation, its inspection & connections, water and air pipe lines, cable tray formation and fittings etc.
Recruitment of Local manpower and trained them as per our requirements
Production & Productivity: Monitoring operation, production and productivity of Tape Plant, loom, lamination, Bag cutting and sewing machines and Printing etc.
Product development: Woven Sacks development as per customers specification and best competitive profitable price and its control to retain existing customers.
Salary and wages: Salary and wages administration, time keeping, monthly muster roll, maintaining leave records of pay roll employees per factory act.
Marketing :
Marketing from developing new customers, sales to collection, develop market by direct marketing campaign, meeting with local dealers and factory consumers, participation in conference and seminars etc, implementing marketing strategies, developing new markets, cash collection etc.
Monitoring competitors activities constantly and keeping top management updated with adequate information’s
Generating the MIS report to enable the top management in strategic decision on penetrating new market, products development, pricing etc
Raw material: As per sales and production plan, prepares the quantity of PP/ HDPE/ LDPE, CC, master batches require for at least two month
Implementing top management strategies in privacy
Preparing sales and technical presentation for sales monthly
Machine spares and consumables: To monitor and ensure availability of imported machinery consumables and spares parts stock in line with production requirements of customer demand, projected sales and target stock holding
Process strategies: In a steady operation stage define, recommend and implement new process strategies for plant reliability, production efficiency and safety.
Daily reports analysis: To examine all reports, operating controls and composite figures to initiate improvements or corrective action where required and to maintain effective control of expenses in line with budget objectives
Handling grievances of workers regarding wages, salaries, medical and other man power problems
Communication: Maintain a good communication with our buyers, purchasers, bankers and also with our production and maintenance team to achieve the targeted production and quality, Participate in production status meetings as required for information exchanges purposes
Reporting: Prepare a well summary report of Daily, weakly and monthly production, maintenance ,manpower, Power, Wastage percentage, Store and other expenses, Raw material, w.i.p and finish stock, Loss analysis and major problem and its remedies etc
Work environment: Ensure a safe and clean work place and respect all environmental requirements.

Key responsibilities for Maintenance:
Here also fully responsible for breakdown and preventative maintenance of Tape plant, lamination plant, Looms, Auto cutting and stitching machines, Printing machines, 560 KVA Gensets, Chilling plants, RO plants, Compressors and all other utilities.
Spare Procurement: : To maintain minimum spare stock level of both imported and local spares for T/plants, looms, Botheven stitching machines, Generators etc and timely place orders and follow-up with purchase to release payments so that production will not affected.
Safety: To ensure that adequate safety and security measures have been installed to protect factory personnel and property

Achievements:
Started production with untrained unskilled Nigerian locals and started training and within 4-5 month we achieved 82% efficiency in loom and 100% efficiency in Plant and Finishing.
Within 6 months of factory started production, and we become the brand name for quality products.
Increases sales from 200Ton to 350 Ton per month within a year
Penetrate with existing woven sacks market successfully by maintaining product quality with reduced price by using Reprocess polymers and CC up to 40%

Works Manager
April 2001- June 2005
Mayur Extrusion Pvt Ltd.
Company Profile: Mayur Extrusion pvt. ltd an ISO 9001-2000 company producing PP/ HD WOVEN SACKS and Zero defect fabrics, Tarpaulin, LINERS, FIBC, etc having 3 production units in Gujarat having monthly production of more than 3200T exporting 90% of the goods to all European countries Bag inspection and approval by Inspection Syndicate of India.

Key Responsibilities:
Production and raw material planning, inward logistics and control, input management (R/m, wip and finished goods), ensure in process and final product quality., maintenance of process plants, looms and other machineries, inventory control, lassoing, technical breakdown attendant, Production & dispatch planning etc.
Preparation and execution of preventative maintenance programs for DG sets, Tape Plant, water treatment plants, HVAC equipments, installation and commissioning of new pants and machines, up gradation of existing plants and machines etc
To examines all daily reports, operating controls and composite figures to initiate improvements and corrective actions where required and maintain effective control of expenses on line with budget objectives.
To establish procedures as per ISO requirements and fulfill all te requirements by proper documentation.
To define the job responsibility for each and every employee and take accountability of each one of them.
To achieve zero defects at customers ends by continuous workers and staff training, monitoring and increase workers awareness about product quality and customers needs
To reduce M/P by automatisation and time and motion study

Tape plant / Maintenance in- charge
Jan. 1996 - Mar. 2001
Company Profile: Jai Corp Ltd.
Company Profile: A leader manufacturer of Woven Bags, FIBC and Liners
Key Responsibilities :
Preventive and trouble shooting maintenance (both Mechanical & electrical) of the followings:
Tape & winders Lorex 1200 and Lohia winders
Lamination plant 850 mm
Reprocess plants
Looms HDN 4 and LSL6
Chilling Plants, Compressors n cooling Towers
Pumps, motors,
Grinders Heat exchangers
Electrical Panels, drives And From 1999 assigned responsibility for the production of Tape plant, Looms and lamination.

Maintenance Supervisor
Aug 1994 – Dec 1995
Vandana Plastics Ltd
Company Profile: Producer of PP/HDPE cement, Sugar and laminated fertilizer bags at Raipur, Chattisgarh
Plant and machine: Lohia Lorex 1000 plant: 04 nos and Lohia HDN 4 Looms 142 nos
Responsibilities: Under the guidance of Maintenance In charge work in breakdown and preventative maintenance in tape plants, Looms, compressors and other utilities

Future Goals

To obtain a position where I can maximize my multilayer of technical and management skills, quality assurance, product development in Plastics manufacturing, maintenance and marketing specially in Woven Sacks and Fabrics, Poly bags, Geo textile and other plastic items. I am keen to achieve further professional development

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