Ref. No. : CA - 27146 - (Costing – with 18.5 years in Plastic Industry)

Education

B.S in (PCM), PGDTQM, LSSGB

Skill Sets

Quality Assurance, Quality Control, SPC, SQC, Implementation of QMS, Internal Auditor ISO 9001, Production planning, Supplier evolution, Sub Supplier development for resources. Quality trainer, Plant coordination, Team Management, TQM, Control chart, Quality Tools. Process Validation, DOE, VA & NVA Analysis , CEPQ, CRPQ & COPQ Analysis and improvements.

Cost Optimization, Process Optimization, Process Validation, Process standardization .OEE,OTD, Sustainability, Quality &HR Compliance.

MS Office (MS Word, MS Excel, Power point) ERP Through SAP system.

Work Experience

Manager-Post Moulding Operations
Since 15th Aug 2019 on going
Company profile- one of the top Business Networking

Job profile-
Build an operational team such a way that they are effectively work towards the Goal or successfully for organization
Define and ensure perfect state of unit assets through preventive and corrective maintenance of all equipment
Facilitate and support implementation of new systems and process improvements like, KANBAN, 5S
Ensure target achievement as per production standards with optimum utilization of resources
Provide leadership for successful day to day operation of the facility.
Monitor daily quality and delivery schedules - Liaison with the Quality team to address chronic issues
Analise day wise rejection and recommend corrective actions.
Ensure timely procurement of materials required for processing of orders.
Prepare Unit maintenance plan in consultation with the Production & Engineering team.
Coordinate with maintenance departments for resolution of any technical problem such as stoppage of machinery/ equipment,
leakage, breakdown address escalations and take corrective actions.
Work towards ensuring cost savings in variable costs through innovative ideas and optimum usage of raw materials, tools and
consumables.
To develop and implement short- and long-term plans to ensure that the Plant has the necessary resources to meet business
objectives and to participate in annual business planning and budgeting of the plant.
To develop and implement short- and long-term plans to ensure that the Plant has the necessary resources to meet business
objectives and to participate in annual business planning and budgeting of the plant .
To oversee quality testing of all incoming materials, in-process product and of finished product with regards to defined
parameters and provide support in case of any discrepancies/ issues.
To ensure reductions in scrap cost, in- process wastage cost, maintenance cost, Energy cost, etc.
To regularly monitor the Plant MIS for tracking the cost.
Provide direction to the manufacturing team for effective operation and achievement of production targets.


Operation Manager
Since Aug 2017-14 Aug-2019
Company Profile:Manufacturer of plastic as well as Metal product Manufacturing such as Thermos Bottle, Lunch Pack, Dinner Set, Water Jug, Children Product Etc. supplying product to customer Like D-Mart, V-mart, Big Bazaar, Amul, Welkin, Pigeon Industries Private Ltd. etc.
Job Profile:
Overall responsibility of Both Plant Unit-I & Unit-II Unit –I having 15 nos. Plastic injection molding machine with 2 nos. of stretch blow molding machine, Two PU Filling line, Five Assembly line including 200 manpower. And Unit-II having Metal component producing machine, one Pipe Making machine, 4 pipe cutting and sizing machine, 2 Pipe blowing Machine, 2 Hydrolic Pressing Machine, 2 Assembly line for neck threading and sizing. and also small toll Room having 5 Ledge Machine and one surface Grinding machine.

Key Performance Area
Responsible for planning for controlling of costs through scrap reduction and enhancing unit production capacities.
Provide guidance / approvals required to achieve the production targets and ensure timely deliveries to the customers.
Participate in new product / design development along with the Customer and sales team
Define and ensure perfect state of unit assets through preventive and corrective maintenance of all equipment.
Plan manpower deployment along with Human Capital team to achieve the production and maintenance targets.
Facilitate and support implementation of new systems and process improvements like, Kanban, 5S 
Ensure target achievement as per production standards with optimum utilization of resources.
Provide leadership for successful day to day operation of the facility.
Analyze day wise rejection and recommend corrective actions.
Monitor daily quality and delivery schedules - Liaison with the Quality team to address chronic issues.
Identify and take necessary actions for continuous improvement in production process
Ensure timely procurement of materials required for processing of orders.
Ensure daily monitoring and reporting of total production in the unit. 
Prepare Unit maintenance plan in consultation with the Production & Engineering team
Coordinate with maintenance departments for resolution of any technical problem such as stoppage of machinery/ equipment, leakage, breakdown address escalations and take corrective actions 
Plan and implement machine/ process engineering initiatives- identify ways to increase the production capacity through effective asset maintenance 
Participate in cost estimations, negotiation for components and tooling as well as development of vendors 
Work towards ensuring cost savings in variable costs through innovative ideas and optimum usage of raw materials, tools and consumables.

Planning:
To develop and implement short- and long-term plans to ensure that the Plant has the necessary resources to meet business objectives and to participate in annual business planning and budgeting of the plant 
Coordinate with product development team to develop new product and plan to meet the customer requirement with cost.

Production:
To develop all necessary policies and procedures to ensure that the Plant, equipment and the resources are effectively utilized to ensure maximum production efficiency and quality targets are achieved as per plan
To plan and ensure adherence to preventive and predictive maintenance schedule and obtain highest degree of customer satisfaction.

Quality management:
To oversee quality testing of all incoming materials, in-process product and of finished product with regards to defined parameters and provide support in case of any discrepancies/ issues 
To meet PPAP requirements of the customers.
To ensure adherence to quality standards like ISO 9001: 2015, 14001, OHSAS etc.

Cost Savings :
To ensure reductions in scrap cost, in- process wastage cost, maintenance cost, Energy cost, etc
To work with the Plant Purchase team for ensuring most cost effective purchase of materials/ non BOM items
To regularly monitor the Plant MIS for tracking the cost.

Plant Administration and Management :
To identify and prioritize tasks and activities involved in the day to day operations of the plant
To ensure effective coordination of the various departments in the Plant to ensure synergies that will positively impact the Plant
To ensure adherence to safety, environment and health standards of EMS/ OHSAS and regularly monitor the same
To conduct the Safety Week in the Plant in line with the Safety Policy of the organization.

Process Excellence:
To lead the implementation of new systems and process improvement measures like KANBAN, 5S etc. at the Plant .
To form CFTs in the Plant to address specific issues or to undertake improvement projects in the Plant to ensure cross- functional participation in process/product improvement.
To ensure adherence to safety norms by all personnel in the department so as to achieve the zero accident goal.

Process Efficiencies:
Reduction in RM+SFG+FG inventory and stock
Monitoring Day To Day Operation Activity and process efficiency
Monitoring OEE on weekly basis and make action plan for improving OEE.
Efficiency in Operations & Asset Maintenance
Reduce scrap to increase profits
Optimal utilization of all assets / machines 
Reduction in quality cost
Reduction of all operation Cost.
Finding the process gap in each operation to improving process efficiency and productivity.
Monitoring the process capability of all process monthly basis.

Inventory Management & Logistics
Monitor and account for inventory of raw materials, engineering spares, finished goods. 
Ensure accuracy of material disbursement for production 
Highlight and take corrective actions in case of stock accumulation, discrepancies and abnormal consumption discuss with procurement and stores team
Minimize obsolete, surplus and scrap material through proper monitoring.
Participate in vendor selection and evaluation process for the unit based on requirement 
Coordinate with planning team / unit planners to ensure appropriate allocation of job machine wise, based on delivery schedules 
Ensure timely dispatch of material to the client. 

Strategic:
Provide direction to the manufacturing team for effective operation and achievement of production targets.
Responsible for achievement of production targets as per the defined budgets.
Drive a customer focused work culture throughout the unit 
Design and implement systems and processes to bring out higher machine efficiencies, quality improvements and reduction in wastage on a continuous basis.
Plan and implement systems and processes to meet legal compliance and industrial safety norms in the plant
Responsible for compliance with safety and hygiene norms established by the company
Participate in new product / process/ design development along with the NPD team .
Responsible for skill development, acquisition and retention of key talent.

Manager - QC
Nov 2009 to July 2017
Company Profile: Plastics product manufacturing company such as barby doll, VIP Bag, cosmetics parts, IKEA house hold parts, Hanger etc.
Job Profile:
Ensure that the Processes needed for the QMS are established, implemented and maintained as per ISO 9001:2008.
Coordinate with all sections / Departments for Implementation and Maintenance of QMS.
Ensuring Promotion & Awareness of Customer Requirements throughout the Organization.
Plan & Organize Internal audits and appraise the Top Management of the Out Come of audit Results.
To provide Guidance to all the departments’ for Quality System documentation & Implementation.
Customer Complaint Analysis and take Corrective Actions for Process/Product Improvement.
Responsible for Removal of Non Conformists in manufacturing operations in case of Non Conformity.
Procurement & Calibration of Test Equipment's.
To takes Care of Customer requirements proactively.
Preparation of rejection analysis, work instruction/procedure for QC work, corrective action on customer compliant, hold reports, quality issue reports etc.
Training of all QC Engineers for system implementation and one page solution of all problems.
Responsibility for MSA
Responsibility of control & monitoring document of Quality System.
Responsibility of data analysis by using 7 QC Tools.
Basic knowledge about 6’s
Responsibility for SPC CP, CPk programmed for process to reduce the rejection and wastage.
Responsible for SOP, WI, & Quality Manual.

Capabilities & Motivation
Informal leadership, high energy and drive to work with and through the organization and with suppliers, to reach common goals.
Sense of urgency and a never compromise attitude towards quality
Eager to actively search for information and continuously learn from good examples and mistakes
Striving for personal development and applying new learning’s in area of expertise
Capability to perform analysis and draw conclusions to support the right business decisions and implementations
Have a holistic view, always having Customer, Supplier, compliance and quality development in mind
Result oriented with energy and drive to deliver better products for the many people
Have a sound judgment; being honest with high integrity, to take decisions for non-compliance even if it have a business impact
Motivate and inspire suppliers and business development teams to continuously maintain and improve Quality performance
Willingness to develop and grow within my organization.

QC - Engineer
Aug 2008 to Nov 2009
Company Name: Shaily Engineering Plastics Ltd.

QA - Executive
Apr 2005 to 30th Jul 2008
Company Name: Time Technoplast Ltd.

QC - Officer
June 2003 to March 2005
Company Name: Jyoti Plastics Engineering works Pvt. Ltd.

Professional Summary
Experience in plant operation, quality control, quality assurance, quality management, ISO auditor, Audit, Training for quality system implementation, System implementation at plant, Production management, Rejection Analysis by quality tools, co ordination with product development, internal logistic, Time study analysis, people management. Core member functionality, Six sigma Project work,
Adopt at working in high pressure environments with strict deadline.
Result oriented with dynamic leadership, process control, supplier development, Skill set improvement in reputed organization in various Manufacturing and packaging industry.
Recently taken training of awareness program of ISO 9001:2015 from Intertek.
Completed Lean Six Sigma Green Belt Certification from Six Sigma Bench Mark (LSSGB).

Area of Expertise:
Achieved target of production through proper planning of 3M (Man. Machine, Material etc.)
Implementing Various SPC tools and new techniques.
Monitoring Continual Improvement through COPQ, CEPQ, KPI, and Customer Feedback Analysis.
Implementing and maintaining quality management System in line with end customer expectation.
Training and education quality management system within the organization and with vendors
Internal as well as external Calibration of equipment, machine
Preparation of all documents and records as per customer requirements and as well as organization Policy.
Process Validation and Implementation.
VA & NVA analysis.
Process Map, Process Flow, SIPOC.
OEE & s Calculation.
Vender Development and Evaluation.
Cost Saving project by implementing Automation and Kizen.
Secure knowledge sharing and competence build up regarding Product Safe & Health requirement with co-workers and suppliers and Lead training with co-workers and suppliers to develop Competence about.

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