1994-95 Post Diploma in Plastics Moulding & Mould Design from CIPET, Bhubaneswar, All India – Third Rank
Senior Level Management Professional in Plastics Manufacturin, Specialization in OEM’s/Pails/Automotives&Advanced Painting Operations /Strategic Planning / Project Management etc.
Certificate course for Internal Auditor conducted by Under Writers Laboratories, USA.
AutoCAD from CIPET.
General Manager – Operation
May 2012 to May 2017
Job Profile :
Manufacturing/Operations/Project Establishment etc. - Plastics Injection Moulding Machines Range - 60T to 3200T
Selected machines by taking advantage of the latest state–of–art technology, directly managed adherence to product specifications and timelines along with establishing manufacturing control plans by reviewing the specifications.
Restructuring in terms of technological up gradation, implement right process in the organization.
Finalise the Plant Layout based on Lean Management System with objectives as follows:
Reduction in throughput time, cycle time or lead time
Reduction in the cost of space, inventory & capital equipment.
Increase in capacity utilization and Develop a Technical Financial Budget for Machines & Ancillaries
Job Profile & Role Clarity of all the Expats by handling of multiple location plants, marketing, logistics, operation finance.
Manage Design related tasks including planning, control and troubleshooting.
Conduct research to incorporate improvements as per the product requirements.
Monitor product quality & impact of design modifications on product features.
Worked on quality control to ensure that all requirements are met. Create superior shareholder value by growing market share through improving production techniques and cost cutting methods.
Successfully identified the root cause of the production loss and increased the tonnage of monthly production from 550 tons 800 tons to Optimize & utilize the 90% capacity.
Successfully implemented Kaizen methodology to achieve the world class manufacturing facility.
Work space by implementing 5k, achieved 20% extra space and reduced the waste fully activity approximately 30% and Totally changed the house keeping of the plant within 3 months by using 6 S principles and through visual management technique of kaizen.Inventory- Reduction by 18% which resulted in cash flow.
Improved productivity nearly 85% by using Autonomous Maintenance which is the key step of (TPM) Total Productive Maintenance Methodology.
Successfully handed new factory development project to shift all IM related machines and activities to one place and form as SBU.
Capably restructured customer service department & improved the level of service delivery to 90% which resulted in getting 10% more business from the present customers in terms of new products development and additional sales.
Successfully negotiated with employees without effecting the operations, which resulted in reducing the permanent employee cost & arranged for a contract labour for some of the operations which reduced the fixed cost drastically.
Actively involved in Energy Conservation Projects to ensure sustainabilility. Successfully handled MIS, P&L & Costing department to reduce production cost by implementing different solutions to improving the productivity and reducing other costs like electricity, materials cost and minimize other wastages.
Successfully reduced per piece cost through controlling process variability, reduce rejection and changeover time by SMED
Implemented Docile Process - inventory through inline integration of processes i.e., in–line mixing as well as in-line assembly. Set the goals for the company in line with the policy and set the departmental goals in line with company goals.
Played a key role in conducting training programmes and group meetings to address concerns in technical environment; provided leadership and ensured project success. Changed low moral team into highly motivated team through continually monitored training programs which helped to reduce the frequent turnover of the expat manpower.
Deftly preparing cost working sheets for components based on quality and effectiveness.
Project managed introduction of new products and new product concepts to all major clients and agents.
Handling the customer service department to improve the level of service delivery to highest level.
Developing the volume &profitability of overseas market sectors through more effective sales and marketing campaigns.
Awarded manpower for special commitment and outstanding achievements.
Holds the distinction of developing tailor made vertical insert moulding machine - to cover plastic on Copper Battery Terminal ICC (instead of lead plating), thereby saving INR3.0cr/Annum.
Stellar in increasing productivity by 15 to 20%, adopting ‘Lean Manufacturing Strategy’ and Key Performance Indicators (KPI’s) such as stock turns, inventory accuracy, reject rates, cycle time efficiency and equipment utilization were established.
Essayed a key role implementing the Overall Equipment Efficiency (OEE) of 82% and material efficiency level of 99.5%. Saving of 26% energy through detailed exercise. Reduced Raw Material Cost and Saved Company INR 1.8cr per annum
Pivotal in design and development of formulation for Halogenated Flame Retardant Master Batch & Composite Plastics, in use of manufacturing of automotive components.
Equipped Manufacturing Infrastructure & Production of Master Batch Plant on Twin Screw Extruder. Reduced Operational Cost and Saved Company INR 1.2cr per annum
Since supply of skilled manpower to operate and maintain machines is far in short of demand, we need to make our process Unit simple to understand for the ‘not so skilled’ People.
Played a pivotal role in central design department Understanding the users unique need,
Deftly engineered cost savings by developing PP moulded – copper ICC inserts, to avoid lead plating operation for connecting battery terminals applying KAIZEN SYSTEM.
Analysation of feasibility & study on the part, tool and functions for precise mould manufacturing and multi-cavity hot runner moulds.
Mould flow analysis to ensure the part filling results for a better understanding of their final product.
Process planning for manufacturing that helped in maintaining superior standards in Quality & time.
Plant Head/DGM – Operations: Plastics Division : Oct 2008 to April 2012
Manager –Production/Green Field Projects/Developments –Plastics Division : June 2004 to Sep 2008
Assistant Manager – Production/Projects - Plastics Division: Jan 2002 to May 2004
Senior Engineer – NPD - Plastics Division : May 1999 to Dec 2001
Company Name : HBL Power Systems Ltd.
Job Profile :
Implemented systems on control of poor quality costs through best manufacturing practices.
Significantly formulated innovative plans to identify key areas to quality for higher unit levels with major vendors, gaining significant cost savings for the entire corporation.
Provided targeted cost with unit levels needed of schedule of savings per component for selected products based on ABC classification of analysis.
Collected technical date in all aspects and analyzed the technical requirements.
Production Engineer – Plastics Manufacturing
April 1997 to April 1999:
Company Name : Innovative Polymers Pvt. Ltd.,
Tool Room Engineer – Moulds Designing & Manufacturing
Aug 1995 to Mar 1997:
Company Name : Mold–Tek Plastics Ltd
Training & Seminar Attended:
Management Accounting including Working Capital Management, Inventory Management, Budget Management, Ratio & Cost Volume Profit Analysis and Decision Making skills.
QMS, EMS and OHSAS Systems.
Development of Management Skills: Improvement of Leadership Qualities, Team Building and Communication Skills.
Areas of Expertise
Strategy Planning/ Project Engineering:
Monitoring projects with respect to cost, resource deployment, time over-runs, quality compliance and manpower planning to ensure timely execution of projects.
Handling the planning, scheduling and management of setting up green field & capacity expansion projects, ensuring completion of assignments within time and budgetary parameters.
Analyzed ROI and made recommendations on capital project requests at various investment levels.
Assessing the performance of vendors based on various criterions such as cost, delivery, quality improvement rate, etc.
Production and Process Enhancements:
Supervising production related tasks (plastic) including planning, control & troubleshooting, painting, material planning, vendor development, etc. for achieving the planned periodic schedules and process control.
Monitoring the production status, procedures and systems followed in production to ensure compliance norms with desired quality and timely delivery of orders.
Developing new process concepts for production optimization, yield improvement and developing guidelines for the sequencing of manufacturing activities.
Improved efficiencies through the implementation of standardized work and a cost control system that was integrated to the MRP system resulting in a 50% headcount reduction in the department.
Developed an Activity Based Cost model for the allocation of overhead by product, enabling products true costing to be better understood and pricing to become more competitive.
Identifying scope for Planning / implementing technological changes to enhance efficiency & Modifications in equipment’s, process flow, working practices, consumables etc. for controlling & reducing conversion cost per unit produced.
Implementing various techniques for cycle time / cost reduction, entailing identification of opportunities, analysis of data, conducting tests, cost benefit analysis and implementation.
Purchase & Material Management:
Planning and controlling all requisite activities i.e., raw material purchase, to perform such as techno – commercial evaluation, negotiation, recommendation, ordering, inspection, expediting & tracking, reporting, delivery, payments processing, etc.
Assessing the performance of the vendors based on various criterion such as percentage for rejections, quality improvement rate, timely delivery, credit terms, etc. Overseeing follow-up with vendors for engineering deliverable, timely deliveries, quality checks.
Directing and leading the technical personnel. Imparting continuous on job training to the workforce for accomplishing greater operational effectiveness / efficiency.
Working on talent pool and succession planning of the management cadre and workforce, appraising their KRA based performance and providing feedback on the same.
A result oriented professional with 25 years of qualitative experience in Strategic Planning encompassing Plastics Operations from Conceptual stage to end result in all Moulding Processes along with Design & Manufacturing of Moulds, Specialization in Pails, OEM Components, Automotive field, Painting, Development of Raw Materials, Project Establishments, Process Enhancements, Value Engineering, Product Costing /Cost Reduction and Team Management.
Travelled across Global for Technical up gradation & Continual Service Improvement.
Core experience with many different makes of injection moulding machines including, Mitsubishi, JSW, Krauss Maffei, Windsor, Ferromatik Milacron, L&T, Jet Master, FuchinSin, Golden Eagle & also vertical injection machines. Most experience in custom moulding shops with all types of moulds- stack, hot runner, multiple core pull, insulated runners, valve gating etc. Expert at trouble shooting of both Engineering & Commodity Plastics.
A keen strategist with expertise in managing entire production & project operations with key focus on top line & bottom line profitability by ensuring optimal utilization of resources. Proven abilities in enhancing production process operations, optimizing resource & capacity
, escalating productivity & operational efficiencies while curtailing costs & expenses. Expertise in managing technically advanced cost-efficient, state of the art production & Core experience in implementing best manufacturing systems.
Areas of Excellence:
Strategic Planning & Management
Business Systems Analysis
Operations & Engineering
TPM/Advanced Manufacturing Systems etc.
Manufacturing / Project Management /Inventory Management
Continual Improvements/ Value Engineering/Cost Reduction
eam Management/New Initiatives
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