Ref. No. : CA -
27079 (Production - Dies & Tools with 18.8 years in Plastic Industry)
Highest Education Level
Masters - Degree
MBA (Operations)From Mod - Tech Institute of Management, Pune, in 2015 with 67.12%
Bachelor in Plastic Engineering From College of Mod –Tech Engineering, Pune, in 2008 with 64%
Diploma in Plastic Engineering From ISTM, Pune, in 2004 with 82%
Diploma in Electronics Engineering From Cusrow Wadia Institute of Technology, Pune, in 2001 with 60.27%
A Highly confident, self-motivated, result-oriented with well documented having 18 yrs. experience in polymer and plant production with assembly operations.
A competent professional with over 18 years of experience in the areas of Operations Management - Molding,assembly,paint shop and tool room,Production planning,Plant Maintenance, Quality Management,Material Planning and Team Management. A strategic planner with expertise in managing production activities, streamlining processes / procedures to facilitate smooth production process & enhance productivity.
Rich experience in implementing quality management tools.Establish, maintain & improve quality systems as per IATF16949:2016 standards and promote continuous improvement projects to improve Quality Management System.
An effective communicator with excellent relationship management skills and strong analytical, problem-solving & organizational skills.
Conversant with MS Office 2007 & professional, SAP,ERP Systems and Internet A
Work Experience Details
Plant Head - GM – Operations
Since Dec 2016
Company Profile : Manufacturer of Injection Moulds and Injection Moulded Thermoplastic Components.
Job Profile :
Reporting to Managing Director
Improvement in operations department and meet the operational budgets of production, quality and safety.
Ensure Zero customer complaints. Produce require quantity with standard quality.
Meet the unit targets of efficiency, scrap, maint. Cost, service levels and outsourcing cost. Reduction in operational cost as manpower, raw material, Power, fuel, consumable, premium freight and over heads…etc.
To meet monthly sales target. Dispatch planning and monitoring.
To Keep continues focus on 4M change.
Improve the technical and managerial skill of team members. Team management.
To Ensure OEE of each equipment as per target. To keep all equipment's healthy and productive.
Meet the unit profit and loss targets.
May 2014 to Dec 2016
Company Profile : Manufacturer of automotive solutions to original equipment manufacturers. The Company offers a range of products across various verticals of auto components, such as switching systems, acoustic systems and alloy wheels etc.
Job Profile :
Reporting to VP-operations
Mar 2011 to May 2014
Company Name : Varroc Lighting Systems India Pvt. Ltd.
General Manager –Operations (Head - 4: Plant Operations)
May 2007 to Mar 2011
Company Name: Attitude Plastics Pvt. Ltd.
Company Profile: Specializes in Plastic Injection Moulding, with all types of raw material and Moulds. The company manufactures engineering plastic products; Battery Components. Customer are Exide Industries Ltd. (All Group),TACO Group Visteon etc.
Job Profile :
Assistant Manager (Molding)
Aug 2003 to May 2007
Company Name: Bericap India pvt. Ltd.
Company Profile: Manufacturer of world class high value added plastic closures (caps), preferably with own proprietary technology. Customer are coca-cola, Pepsi, Veedol, BP, HPCL, Castrol, SHELL, Volvo- line & Bisleri etc.
Job Profile :
Reporting: Plant Manager.
Assistant Manager: Production
Aug 2003 to May 2007
Company Name: Lumax Industries Ltd.
Company Profile: An ISO 9001:2000 Company engaged in manufacturing of Automotive Parts (Lighting Parts), under the license from Stanley Electric Company Ltd. Japan. Having the clients like Tata Motors, Ashok Leyland, John Deere, Mahindra & Mahindra, Bajaj Auto, Ford Motors, Honda etc.
Reporting: Production Manage
Technician - Molding
Nov 2001 to Aug 2003
Company Name: Varroc Engineering Pvt. Ltd.
Company Profile: Involved in manufacturing plastic components for Automobile & home appliances companies like Bajaj Auto, TATA Auto components, Tata Toyo Radiators, Videocon, National Panasonic, Kirloskar Mahale, M& M etc.
Tasks Handled Across the Tenures:-
Heading overall operations including administration with a view to ensure timely accomplishment of production targets within the time and cost parameters.
Monitoring OEE on daily basis & making action plan for its improvement in co-ordination with other Departments.
?Determining the future needs and production capacity for producing required quantities of items on pre-defined standards within financial costs.
Managing resources to perform manufacturing activities in cost effective manner.
Maintaining the documents in accordance with the required standards.
Process mapping to identify & eliminate the non-value adding activities in the operations.
Production Planning & Control:
Planning day-to-day strategies, budgets, production schedules, along with resource allocation and machine loading for optimum output
Capacity planning for new projects as per customer requirement.
Monthly production planning of Mould Shop, Press Shop, Assembly & vendors as per customer requirement and the stock available at various stages of operation.
Raw material, BOP & Packaging material planning and release it to Purchase Department.
Planning for the subcontracted parts as per stock available.
Release of weekly production plan to shop floor people and daily monitoring of Plan Vs Actual.
Follow up in advance with the various departments like production, Tool Room, Maintenance, Purchase, Quality for any constraint to prevent delivery failures.
Continuously improve the production Planning process as per the inputs from various departments.
Raw material reconciliation at various stages of operations to know the exact output at individual stage.
Inventory control at various stages of operation from Raw Material to finished product Work Order management in ERP system.
Planning & implementing the preventive & predictive maintenance schedules for improving the overall reliability and safety of plant equipment’s.
Managing the erection and commissioning of a wide range of machinery, viz, Production machines like Molding Machines, assembly lines and Utilities ….
Quality System Implementation / Quality Assurance:
Establishing Quality Management Systems across various processes to reduce rejection levels and ensure high quality standards at all the stages of production. Monitoring adherence to various Quality System.
Implementing stringent systems / measures to ensure high quality standards at all the stages of production process.
Rich experience in implementing quality management tools.Establish, maintain & improve quality systems as per TS16949 standards and promote continuous improvement projects to improve Quality Management System.
Team member for implementation of MMA & MSES requirements, which is requirement of M&M.
Design & Development:
Evaluation of the new projects in terms of revenue & investment.
Feasibility review with the team for new projects.
Concept & design verification's for new product development.
Manpower planning,training,proper utilization's and managing.
Developing, managing and monitoring the performance of multi-skilled work force and conceptualizing need-based training programs for performing maintenance/production operations.
Working on succession planning of the workforce, shift management activities, appraising the member’s performance & providing feedback.
Determining the manpower requirement in accordance with manpower rationalization and production norms.
Highlight Of Achievements
Successfully set up 2 green field project i.e. a new plastic processing unit in current company and APPL in chakan MIDC.
Managing Plant activities of 2 manufacturing Units and responsible for profitability of the plant. Plant OEE improved from 52% to 86% in just 6 months. Introduced new process’s to reduce losses due to rejections.
Plant profitability increased from CASH loss to operational profit through implementing productive process techniques, cost reduction, break down reduction, material saving, and process optimization & rejection reduction.
Increasing operational profits by 10% by taking initiatives to reduce overall operating risk
Received several appreciation from clients for Improvement in supplies, No Line stopages and better Quality products
Implemented 21 Lamp Project and 156 tools trial from development to assembly operations.
Played key role in launching of Nissan-QUID project tool development to assembly operations
Received an appreciation certificate in August 2006 for outstanding performance & contribution towards implementation of Kaizen within the company in LUMAX Industries Ltd.
Saved 2.5 cr in last financial year; avoided buying 1 new metalizing mc by realigning work methodology and changed fixture orientations.
Avoid buying 6 new molding machines in last financial year by realigning work methodology, cycle time reduction, process optimization.
Reduced mould change time by 125 minutes to 13.9 minutes (using SMED Tools)
Received Best Performance Award for improving OEE from 67 % to 89 % in VLS.
Successful in running six injections molding machines in fully auto condition by correcting the moulds for zero reworks & free wall ejection & this achieved a reduction in manpower from 6 to 2.
Played in major role in Cut down wastage/scrap levels from 23% to 2.1% by realigning work methodology, process optimization and attitude in the organisation
Executing an important role in increasing product quality levels by introducing process optimization, manpower training, implementation of TPM.
Recognised as the core CFT leader of the Toyota Quality Improvement Zero Defect Project
Acknowledged as the core team member for implementation of MMA & MSES requirements, as required by M&M.
Certificate course in plastic processing & testing from CIPET Centre, Aurangabad in Mar’07
Diploma in Production Management & Productivity from Quality Environment, Govt. College of Engineering, Pune from May’06-Jun’06
Diploma in TPM (Total Productive Maintenance) from Quality Environment, Govt. College of Engineering, Pune from May’06-Jun’06
Diploma in TQM (Total Quality Management) from Quality Environment, Govt. College of Engineering, Pune from May’06-Jun’06
Certificate Course in Creativity & Kaizen from Strategic Management resources & Technologies, Pune (SMRTC) in Feb’05
Certificate Course in Six Sigma–M&M Yellow Belt from Mahindra Institute of Quality, Nasik in Jul’14
ISO/TS 16949:2009 Internal Auditor Training from BLQS Consultancy Pvt. Ltd., Pune in Dec’09
TPM (Total Productive Maintenance), from TPM Guru S.Yamaguchi, Rama International, Aurangabad in May’07.
SMED/Problem Solving Tools/Quality circle/Kaizen, from MIL, Pune in 2015 -16.
Leadership / Managerial Effectiveness / Team Building, from Garudmachi-High places Mgt,Pune in 2014
Green field Project / Start-up operation, Plant Operations, Plant Management, Plastic Technology and Processing, Trouble shooting & Process Improvement, Quality Management, Production Planning, Assembly Operations, SCM, Logistic, Material Management, Team Management, Kaizen, TPM, SMED, DOE, PDCA, Quality Circle, Kaizen, 5S, TPS, Six Sigm, Lean Manaufacturing, Productivity Improvement, QC Tools, Rejection Control, Suggestion Scheme, Visual Management, ISO/TS16949.
Seeking a high profile senior level position in a leading organization where I can utilize my rich manufacturing execellence experience towards making a positive contribution towards business goals. To become a part of creative and innovative organization in which I can utilize my knowledge in plant operations & Individual growth along with growth of the organization.