Ref. No. : CA - 10375 - (Production - Blow Moulding – with 24 years in Plastic Industry)

Education

MBA (Production & Operation Management) From Mumbai University
PGD – PPT (Post Graduate Diploma In Plastic Processing & Testing Engineer) From CIPET
B.Sc From Utkal Unversity (Odissa)

Skill Sets

I have fully knowledge of extrusion blow moulding, computer knowledge ISOTS-16949

AREA OF EXCELLENT-:
1-Strategic Planning and resources manufacturing
2-Operations management
3-Process continuous Improvement  Quality control / Assurance 
4-Resource planning for the operation & Project
5- Man power Management & Plan as per requirement
6-Cost Estimation for new project
7-Team Management for the production & Project activity.
8-New machine supplier selection & Technical discussion
9-New project machinery Acceptance, installation, trial and Resource planning. Layout finalized for the new project Material management in the plant
10-IATF, EHS & OSHAS Documentation, Manufacturing basic,6S
11-LOTO implementation in the operation
12-KANBAN,Kaizen improvement ,SUBO system implement.
13-KPI monitoring & action plan implanted with team for any deviation.
14-Implemented in safety culture.
15-Skill evaluation & Training plan to team for update their skill.

Work Experience

Blow molding In charge
From Nov 2020-Till now
Company profile- Manufacturer of injection molding components, blow molding components, blow molding components.
Job profile-
Production Planning-
?Analyze plan production schedules, processes, documentation, tools etc.
?Preparing monthly production plan and circulation and monitoring for achieving the set targets to meet the customers need.
?Planning to procure the raw material for the required production specification wise.
?Recommend modifications to production process.
?Review of Production vs. Dispatches with quality & safety policies.
?Maintain an awareness of developments in the field of production engineering in the area safety & department objective.
?Analysis KPI against daily production activity.

Plant head Blow molding
From 2019-2020
Customer –TATA, FORD, EICHER, MAHINDRA, VOLVO Fuel tank & Adblue tank for Commercial vehicle.

Kautex India Private Limited(2014-2019)
Post for – Manager Production & Process
Customer –FORD B562 project (India & Europe) for FORD FIGO & ASPIRE Mahindra & Mahindra SCR tank

ABHIJEET PLASTIC PVT LTD(2014-2014)
Post for -Blow & Injection molding Manager (for 4 months only)
Production -Automotive parts-Duct. Mudguard, bumper, and Front grill

Senior Engineer Production
Since Oct. 2010 to 2014
Company Profile: Manufacturer of automotive fuel tanks.

Blowing Factory Production Manager
2008 - Sept. 2010
Company Profile: Blow Moulding & Injection Fittings Manufacturer.
Customer: Drinking Water jars, Plain Straw & Flexible Straw.
Product Range: 5 & 6 Gal PC Gallon, 5 Gal HDPE Gallons, 5, 10 & 20 Litr, 500 Ml & 1 Lit

Shift In-charge
July 2006 - 2008
Organic Plastic Industries Ltd ( ISO 9001-2000)
Company Profile: Blow Moulding & Injection moulding Product Manufacture.
Customer: Castrol India Ltd, HLL, BPCL LTD, IOCL LTD, Gulf India Ltd., Bharat Shell Ltd.

Job Responsibility:-
Establish an activity plan and report monthly against that plan.
Troubleshooting, QMS knowledge, good hands on experience in handling latest technology blow molding machine.
Manage a group of workers, deploy them on respective works.
Monitor and set Process Parameter for all production machines to optimism production.
Monitoring Production target, Production Planning, Process measurable.
Handle Mould changeover based on production plan and marketing requirements.
Monitor Rejection levels (PPM) within acceptable limits.
Monitor production operations and ensure proper reporting on shop floor & final inspection as per master sample.
Reconcile utilization of material at shop floor. To ensure consumption is within target levels.
Maintain & Implementation QMS / ISO Documentation, SOP sheet during dept. (ISO-TS 16949-2009, ISO 14001 & ISO18001
Coordinate with various internal departments for design, engineering related issues within set time schedule.
Developing new process concepts for production optimization, yield improvement and optimizing
Implement & Monitor 5S, kaizen, 8D & 4M & safety in the shop floor area.
Identifying & solving issues for supplier components that need focused attention in order to reduce rework, rejection PPM & improve productivity
Zero Accident Compliance on Shop floor.
Maintain & Monitoring OEE, OLE, Efficiency, REJ Label & Scrap Level.
Organizing training programs for multi skills of front line & increase competency of managers for effective Utilization of HR.
18 Training and guiding teams towards identifying factors critical to quality, reducing Process variation, improving capabilities & increasing stability.
Leading the implementation of TS 16949 quality systems across various functional departments
Formulating and implementing cost saving measures and modifications to achieve substantial reduction in terms of production cost & energy consumption
Formulating guidelines for the sequencing of manufacturing activities
Meet regularly with line workers to address departmental issues.
Actively participated in auditing of ISO-TS 16949, ISO 14001, and iso18001, TPM.
Undertaking regular Internal Audits, Root Cause Analysis, troubleshooting and reviews to ensure adherence to highest stand.
Work with production planning to maintain cost effective and timely production schedules and inventories
Lean concept & kanban concept involved in work instruction.
Working with managers to implement the company's policies and goals;
Ensuring that health and safety guidelines are followed; (GREEN CROSS & SMS TRACKER)
Supervising and motivating a team of workers; ( OJT)
Reviewing the performance of subordinates; ( SKILL MATRIX)
Identifying training needs.

Production / manufacturing-
Troubleshooting, good hands on experience in handling latest technology blow molding machine in process & production.
Hot plate welding & assay with child part to deliver quality product.
Lead process activities as per planning...
Ensuring the products comply with the required standard (as per work instruction & procedure).
Verifying section-wise process parameters and to ensure all parameters are as per SMP & PMR.
Ensure usages of left over compounds (semi-finished goods).
Suggesting Improvement in production and Reduction in wastage (MUDA, KANBAN & LEAN ACTIVITIES).
Ensure delivery of products as per customers’ requirement with standard specification.
Implement corrective and preventive actions on internal customer complaints, quality problems and any other issues (CAPA ,4Q analysis & 8D,A3 & A4 analysis).
Preparation of various MIS & ERP as regards to productivity, quality, and performance.
Re-allocating tasks whenever needed to achieve deadlines.
Inventory Management verification.
Organizing Non-Conformity review and action plan (Re work instruction & NC part handling work instruction).
Achieve & monitoring OEE, OLE, EFFICIENCY, REJ LABEL & SCRAP LEVEL as per company target (KPI).
Reduce PPM & improve productivity.
Prepare monthly production report & discuss with global team with action plan (MRM report)
Operational compliance:
Maintain plant compliance on operations by defined operating procedures
Ensure compliance on Health, Safety, Environment and Employment regulations
Directs activities related to the manufacturing plant's operations regarding capacity planning, capital and manpower planning, project justifications and financial support, manufacturing cost-
Down initiatives, and metric analysis and visual management
Drive actions towards removal of waste / constraints from the production process to improve efficiency and enhance productivity
Key Performance Indicators (KPIs):
Manpower Planning-
Manpower finalized as per the production line balancing requirement .
Training & Development of the team.
To assess the training need of the employees regards company policy, dept. objective, safety & standards.
Ensure proper training of operators as per plan...
Monitoring effectiveness of training imparted. Working with managers to implement the company's policies and goals (skill matrix);
Reviewing the performance of subordinates; (SKILL MATRIX)
Training and guiding teams towards identifying factors critical to quality, reducing
Process variation, improving capabilities & increasing the productivity with less rejection & down time.
Project Management-
Project cost estimation and lay out finalized
Installation & Commissioning of blow molding, welding, assembly & leak tester (Air & Water, USLT, Helium leak tester)
Successfully completed IR & ER on time.
Newly all department team formed & trained as per system requirement.
Machine run as per cycle time & full fill customer requirement.
Production Line balancing as per customer requirement completed(STW).
Trail arrangement to fulfill customer requirement in new machine & mould trail (SERA).
Engineering change as per customer requirement.
Capacity plan analysis report readiness & submitted in customer (CAS).
New project Layout, machinery installation, trial and sampling.
Project completed below as per planned budget (Only 70 % of total budget)
Implementation of Follow the global technical norms & safety rules as per global requirement at the project

Safety -
Ensure the safety of Man, Machine and Materials, Method (4M).
Train the operators for safety rules and regulations (LOTO &ISO 14001&18001 requirement)
Ensuring the zero-accident level at all times as per company safety policies.
Ensuring that health and safety guidelines are followed; (GREEN CROSS, LOTO & SMS TRACKER)
?Height safety work permit, personal safety, visitor safety compliance implemented.

Quality Management System-
To lead as a Management Representative for implementing the quality management system in the organization.
To train the employees towards the system, importance and compliance.
Compliance on the part Quality Management System and conducting internal audit.
7qc tools& iso ts 16949-2008 & TQM & CPM activity.
Other Responsibilities (Day- day activities):
Analyze and plan production schedules for dispatches in line with the month's business plan.
Review production against dispatches schedule.
Material planning discussion with SCM department - Both RM & BOP parts.
Check WIP and keep control (single flow process) with line balancing.
Check Non-moving excess produced FG
Key in last minute rush orders preferably without upsetting the planned commitment (TAKT TIME)
Should be demanding and assertive to balance between production deliveries and SCM requirement.
Formulating and implementing cost saving measures and modifications to achieve substantial reduction in terms of production cost & energy consumption
Implementation of TPM & TQM activities.
Monitoring Production target, Production Planning, KPI as per department target.
Blow molding process setting. (product fault solve)
Down line run as per cycle time (match STW 100 %)
Co –ordination with plant & customer in all technical activity.
Ensure Production line run as per PPC plan.
Fulfill department objective KPI, Customer requirement & implemented global process standard.
Global meeting attended with department objective with process awareness.
Documentation
Daily ISO-TS 16949, IATF-16949, EMS & OSHAS, documentation for update & implementation.
Daily monitoring department objective KPI. (OEE.OLE, PPM, REJ % & SCRAP,4Q REPORT, AOP, MRM, QOS)
Daily follow production plan vs. act & gap analysis.
Every day entry check ERP & MIS REPORT of production engineer entry.
Check if any A3,8D & PDCA regards process loss & safety, green cross record.
Keep all the record verification ISO- TS 16949 AUDIT, ISO 14001 & 18001 (For EXTERNAL & INTERNAL AUDIT) purpose.
Actively participated in auditing of ISO-TS 16949, ISO 14001, and iso18001, LOTO & 5S.
Undertaking regular Internal Audits, Root Cause Analysis, troubleshooting and reviews to ensure adherence to highest stand.
Check all document update display proper way & proper place a global requirement.
Discuss with supplier any process problem or anything violet global process requirement.
Co-ordination with other department to run smooth production.
Implemented LEAN system (6s/kaizen/ TPM)

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