Ref. No. : CA - 27493 (Production - Moulding with 16.2 years in Plastic Industry)

Gender
Male
Age
39 Years
Designation
Department Head
Highest Education Level
Diploma
Preferred Country
India
Notice Period
30 Days
Education Details
Post Diploma in Plastic Mould Design (PD-PMD) From Central Institute of Plastics Engineering & Technology, Amritsar in 2002

Foundation Course in Mechanical AutoCAD 2000 From CADD Centre, Amritsar in 2002

Diploma in Plastic Mould Technology (DPMT) From Central Institute of Plastics Engineering & Technology, Amritsar in 2001
Skill Sets
Production Planning & Control, Operations & Maintenance , P&L Management
Quality Assurance & Control, Operations & Maintenance
Business Strategy & Execution, Plant Operations, Process Excellence,
Cost Optimization, Stakeholder Management, Reporting & Documentation,
Team Building & Leadership

Certifications
Certified Engineer of Axos System by Netstal Machinery Ltd.
Certified Six Sigma Green Belt from ACMA
Certified Automation Engineer (PLC, SCADA & HMI)

MS Office & Internet Applications
AutoCAD
MFG-PRO

 

Work Experience
16.2 Year(s)

 

Work Experience Details
Department Head
Since May 2017
Company Profile: Manufacturer of plastic & packaging solutions for corporates & consumers.

Plant Head
Apr 2015 to May 2017

Plant Head
Feb 2014 to Feb 2015
Company Name : Sonnex Packaging Nigeria Ltd.

Plant Head
Jul 2011 to Jan 2014
Company Name : Texplas India Pvt. Ltd.

Job Profile :
Formulating strategic plan to advance the SBUs mission and objectives and promote revenue, profitability, and growth; steering the implementation of the same effectively
Managing revenue, PBT, operating cost as a percentage of revenue, cost per unit of production and rejection & rectification as per budget, aiming towards operational excellence
Leading the project/ production operations to ensure timely accomplishment of production targets within the stipulated time and cost parameters
Ensuring placement of appropriate systems and processes for monitoring performance against plans and budgets
Heading the planning for detailed engineering activities and finalization of requirements/ specifications in consultation with Engineering and Production Department as per clients’ requirements
Taking the responsibility of updating history cards of moulding machines and following it rigorously for tracking problems observed in each machine and taking corrective action
Analyzing and troubleshooting technical problems; steering tests & inspections to ensure that the products developed are in compliance with preset quality specifications
Administering functions inclusive of process planning for new products, process machinery selection, facility creations for testing, quality requirements in line with customer requirements
Developing and implementing quality standards and stringent quality control systems for incoming materials to enhance quality of products & reduce rejection rate
Driving modifications in equipment, process flow, working practices, consumables, for controlling & reducing conversion cost per unit
Identifying and developing vendors for achieving cost effective purchases, reduction in prices and timely delivery
Spearheading production activities for strategic utilization & deployment of resources towards achieving organizational objectives; preparing work instructions for operations of the unit and maintaining reports
Steering man-machine balancing operations and ensuring measures towards attaining enhanced productivity
Formulating production plans, schedules and strategies; arranging resources to ensure achievement of targets as per the stipulated parameters
Conceptualizing and implementing effective techniques to attain operational efficiency, improving quality standards and generating maximum cost savings
Conducting failure investigation analysis to identify gaps and implementing corrective measures
Generating effective procedures for preparation and implementation of programs within all areas of safety, health and environment in manufacturing process
Assuring accomplishment of production targets within time & cost parameters; implementing cost saving measures to achieve substantial reduction in terms of production cost, raw materials & energy consumption
Updating history cards of moulding machines and following rigorously to of the problems observed in each machine and extending corrective actions
Evaluating the prevalent manufacturing systems/ processes, identifying loopholes and undertaking result-oriented measures for alleviating the same
Conducting inspections to ensure that products developed are in compliance with pre-set quality specifications
Determining requirements of material for development activities in the tool room & coordinating with vendors for cost effective, timely sourcing of quality material
Establishing quality standards, implementing stringent quality control systems for incoming materials to enhance quality of products & reduce the rejection rate

Highlights:
Scrutinized financial statements to determine progress and status in attaining objectives and revised objectives and plans in accordance with prevailing conditions
Monitored key performance indicators of the moulding section encompassing yield of resin, wastage of product, efficiency of moulding machine, power consumed in injection, stretch blow moulding & blow moulding section
Identified loopholes, extended result-oriented measures for getting rid of the same and documented the same
Drove overall development activities inclusive of requirement analysis, planning, finalizing of specifications and prototype development
Determined requirements of material for development activities in the tool room and coordinated with vendors for cost effective, timely sourcing of quality material
Directed the implementation of various techniques for cycle time reduction; managed energy audits, analysis of data, tests and implementation & post audits

Plant Head
Jan 2006 to May 2011

Sr. Moulding Executive
Aug 2002 to Dec 2005
Company Name : Godrej Appliances Ltd

Major Projects:
Title: Installation of Turnkey Project with installation of Elios & Elion Injection moulding machine with Combination of Injection compression moulds with robotics arms from Netstal, Plastisud & Campetalla.
Project Cost: 5.2 Million Euro’s
Role: Increment in Top and bottom line
Description:With this Project, expected Top line will increase by USD 6 Million/ yr.

Title: Installation of 9-Layer Extrusion Machine from Reifenhauser
Role : Increment in Top and bottom line
Description: Expected top line increased USD 16 Million/ year

Title: SMED-M {Single Minute Exchange of Die or Mould}
Role: Bring down MCO time of 450 Tons Injection moulding M/c.
Description: Brought down MCO time from 3-1/2 hours to 40 min in 03 Phase i.e. 3-1/2: 2, 2: 1, 1: 40 min on 450 Tons M/c for 96 Cavity PREFOM mould. Successfully commissioned & installed Magnetic Platen and developed quick change cooling circuit of mould by using water manifold and multi coupling controller manufactured by STAUBLI.

Title: PET Bottle Manufacturing Plant with the capacity of 01 millon preform & 500K bottles per day
Role:In house manufacturing of PET Bottles for packaging of medicine
Description: The project commissioned & installed Injection & Blow moulding machines. Auxiliary equipment such as Air Compressor (High & Low Psi), Cooling Tower (150 TR Cap), Water Chillier (Blue Box Mfg), Raw Material Dryer, Conveyer Belt & Moulds.

Title: Installation of Injection Moulding Machine (25 Nos.)
Role:Increase production capacity to produce Injection moulded products for Paint & Cosmetic Industry.

Title: Installation of Blow Moulding Machine (07 Nos.)
Role: Increase production capacity to produce Injection moulded products for cosmetic Industry.

Title: 04 liters Paint Pail with reduction of 15 % product from existing product in market
Role: New product Design & Development for Paint industry
Description: Design & Development of new product for paint industry with help of Design & Development Team.

Title: 20 liters (02 Cavity) Paint Pail with reduction of 10% product from existing product in market.
Role:New product Design & Development for Paint industry
Description: Design & development of new product for paint industry with help of Design & Development Team.

Title: Underground Water Cooling Circuit for Machines & Moulds
Role:Developed underground cooling circuit to improve efficiency of Cooling Tower & Chillier
Description: Development of underground cooling circuit for Heat Exchanger of Machines and Moulds.

Title: 20 cavity mould modification to reduce raw material wastage & loading on less tonnage M/c.
Role:Modification required in mould to reduce wastage of raw material in form of feed system & load on less capacity M/c.
Description: Modification of 20 cavity mould by installing yudo hot runner system within existing mould with little changes in mould plates to convert existing semi-automatic process mould to full automatic process.

Title: Development of 16 cavity new moulds to reduce raw material wastage & loading on less tonnage M/c.
Role: Modification in mould to reduce wastage of raw material in form of feed system & want to load on less capacity M/c.

Profile Summary
Enterprising professional with nearly 17 years of experience across Production Planning & Control related plant operations
Spearheaded SBU operations to enhance production efficiency, quality, service, and cost-effective management of resources
In-depth knowledge of plastic processing technology including injection molding, extrusion blow moulding, stretch blow moulding machine (PET), cast sheet line and their auxiliary equipment
Managed Turnkey Projects of Injection compression moulding technology (ICM) and worked on injection, thermoforming (ILLIG), cast sheet Extrusion (9 Layer -Reifenhäuser) & blow moulding machines with husky 96 cavities preform mould & 32 cavities closure mould
Managed entire plant operations in Plastic Moulding Industry with focus on top line & bottom line profitability
Headed the repairs & maintenance of injection & blow moulding machine and their auxiliary equipment’s
Implemented quality standards such as Six Sigma, Kaizen and ISO to consistently meet and enhance customer satisfaction
Expertise in designing world-class systems and implementing process like Ultrasonic Welding, Hot Runner Systems, Gas Injection Moulding
Established a skilled team and motivated employees for augmented productivity and performance
Headed the allocation and implementation of the budgets for the SBU
Directed the savings of nearly US$ 600K/ year by changing Glass bottle to PET bottles for one of the projects
Recorded a reduction of 15% of product wt. from existing product in market by increasing ribs & undercut
Extended coaching vision and direction to the SBU Management Team and monitored performance to achieve growth, service and objectives Implemented quality standards: Six Sigma, Kaizen and ISO
Future Goals
Growth

 

 

     

 

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