• Gender: Male
• Age: 53
• Designation: Works Head (DGM)
• Highest Education Level: Graduate - Degree
• Notice Period: 30  Days
• Preferred Location: Lucknow
• Work Experience: 29.3 Year(s)

Education

HBTI, Kanpur B. Tech (Mech Engg) – 75.34% (Hons.) 1991-1995

Skill Sets

Engineering/ Mfg. Operations, SAP, ERP Implementation, Organizational Development, Quality, SHE, ISO and OSHAS, Strategy Planning, Business Excellence, WCM, M Way, TPM, Process Development, Project Management

Work Experience

Works Head (DGM)
Jun 2019
Job Profile :
Management of Factory – Erection, Commissioning and Operations.
Vertical start-up of green field plant from project stage, erection, commissioning to operations.
Management and operations of co-packers during transition period. Exposure to closure of old units.

Assistant General Manager (O&M)
May 2018 to Jun 2019
Job Profile :
Spear heading all 8 own manufacturing plants across India and contractual operations.
Responsible and accountable for all stake holders and all areas of operation of manufacturing units including supply chain.
Delivering the technical targets with quality and cost better than budget by achieving the stringent and stretched targets of KPI’s & KPM’s with compliance to technical and production efficiencies
Sustainability development road map involving Energy, Water & Carbon footprint reduction, Projects, Capability development in Engineering & Utilities function , EHS program development & implementation.
Annual budgeting for COGS / Maintenance / Capex/ Opex/MEP and controlling losses and analysis/tracking for it against benchmark for the yield.
Preventive, proactive, predictive, corrective, opportunity, breakdown & routine maintenance of plant machineries and process.
Formulation, implementation and monitoring of projects with an objective to maximise availability of plant (OEE)
Developing capability of plant to produce new products by identifying and carrying out required modifications & capacity expansion projects.
Ensuring compliance with various quality, environment & safety management systems in the manufacturing facility.
Coach and implement Lean manufacturing initiatives (TPM) in the organization.
Liaising with statutory and regulatory agencies.
The Attainments:
Turnaround in EBITA from -2% to 8% for manufacturing.
Improved plant utilisation by 15% over the previous year.
Reduction in production cost by 10% with 12% reduction in energy cost.
Reduction in manning headcount by 5 in managerial cadre.
Implemented 5s and AM as per part of TPM implementation.

Head of Maintenance
Jun 2015 to May 2018
Company Name : OLAM International
Job Profile :
Spearheading the Engineering operations into various streams of Factory operations - Engineering, , Environment Health & Safety, TPM, Project Management including utilities.
Commissioning of plant and maximising plant utilisation to design.
Sustainability development road map involving Energy, Water & Carbon footprint reduction, Projects, Capability development in Engineering & Utilities function , EHS program development & implementation.
Delivering the technical targets with quality and cost better than budget by achieving the stringent and stretched targets of KPI’s & KPM’s with compliance to technical and production efficiencies.
Formulate and assist Hub technical for development of new products and ensuring vertical start-up online. Negotiating with OEM and all concerned for the timely execution of project.
Annual budgeting for COGS / Maintenance / Capex/ Opex/MEP and controlling losses and analysis/tracking for it against benchmark for the yield.
Preventive, proactive, predictive, corrective, opportunity, breakdown & routine maintenance of plant machineries and process.
Formulation, implementation and monitoring of projects with an objective to maximise availability of plant (OEE)
Optimise inventory and spare management system for minimum inventory while ensuring availability of spares and consumables at all times
Recruit and foster a well trained and motivated manpower. Key focus on driving, leading, motivating, developing, training, disciplining & counselling of human resource.
Human resource management for optimising availability of heads for operation, leaves, OT, etc.
Developing capability of plant to produce new products by identifying and carrying out required modifications & capacity expansion projects.
Ensuring compliance with various quality, environment & safety management systems in the manufacturing facility.
Coach and implement Lean manufacturing initiatives (TPM) in the organization.
Liaising with statutory and regulatory agencies.
Ensuring 100% Compliance to statutory and regulatory requirements. Obtaining Legal / Statutory clearances & approvals as and when required during projects execution.
The Attainments:
Saving from power generation in F17 over F16 - Annual savings: 68,252 USD.
Saving from power consumption reduction in F17 over F16- Energy Management - Annual savings: 226,030 USD
Radical improvement in maintenance – 57% improvement in MTBF and 26% reduction in MTTR through various system implementation and design changes.
Saving from modification of parboiling cooker sensor – Annual saving-26,838USD
Commissioned full plant in record span time.
Saving of 179,000USD in 2016 through engineering improvement activities.
Increase in plant utilisation from 40% to 89% through engineering practices.
Reduction in energy consumption by 18% YOY in F16.
Received award for best energy improvement and management in OLAM on international level in year 2016.
Reduction in manning expenses by 20% and reduction in OT by 60% on YOY.
Zero accidents and won various internal and external prestigious award for safe working.
Pioneered and implemented asset care, TPM and best engineering activities.
Designed and implemented best practice maintenance vision, strategy, policies, processes and procedures for the green field plant.
Power plant project underway for 4 million USD.

Sr. Manager – Engineering / Manufacturing
May 2007 to Jun 2015
Company Name : Sab Miller India,
Job Profile :
Handling 2 packaging/engineering units at Aurangabad – Pals and Foster units.
Spearheading the Engineering and Manufacturing operations into various streams of Factory operations - Engineering, Production, Environment Health & Safety, Project Management including utilities. PALS unit is most complex unit in SAB India in terms of nos. of manufacturing SKU and planning.
Sustainability development road map involving Energy ,Water & Carbon footprint reduction, Projects, Capability development in Engineering & Utilities function , EHS program development & implementation.
Drawing functional strategic plan for production of 175 SKU’s in co-ordination with central planning and thereby executing plan with quality standards as per SAB Miller global guidelines.
Ensuring quality compliance and ensuring “Moment of Truth” through collaborative approach on AFE, TPO, FSMS and hygiene.
Delivering the production targets with quality and cost better than budget by achieving the stringent and stretched targets of KPI’s & KPM’s with compliance to technical and production efficiencies.
Formulate and assist Hub technical for development of new products and ensuring vertical start-up online. Negotiating with OEM and all concerned for the timely execution of project.
Ensure timely updation of emerging packaging trends and innovations to ensure competitive advantage through identification & selection of new machinery / technologies for improving the existing operations.
Annual budgeting for COGS / Maintenance / Capex/ Opex and controlling losses and analysis/tracking for it against benchmark for the yield.
Recruit and foster a well trained and motivated manpower. Key focus on driving, leading, motivating, developing, training, disciplining & counselling of technical human resource.
Developing capability of plant to produce new products by identifying and carrying out required modifications & capacity expansion projects.
Ensuring compliance with various quality, environment & safety management systems in the manufacturing facility.
Regularly conducting audits to review existing quality, environment and safety standards.
Coach and implement Lean manufacturing initiatives in the organization.
Liaising with statutory and regulatory agencies like Excise, Factory Inspector, W&M , FDA.
Ensuring 100% Compliance to statutory and regulatory requirements. Obtaining Legal / Statutory clearances & approvals as and when required during projects execution. MR for IMS of the plant.

The Attainments:
Savings of ?24.08Mn. in Packaging Material and consumables consumption in F14YTD. Reduction in energy consumption by ~10MJ/HL and power by 2KWH/HL. Water consumption reduction by 0.8HL/HL.
Winner of best visual aspect award and Peti Pati contest (line efficiency) in SAB India for consecutive 2 years.
Stellar role in successful launch of first PET beer in Asia from newly commissioned line.
Winner of 5 consecutive and still holding the best Focussed improved Projects award.
Rapidly scaled up Jump shift in production efficiencies by 12%
Distinguished efforts towards integrating Plant Production, Performance and EHS systems
Successfully increased plant capacity utilization from 60% to 80% along with reduction in scrap from 11% to 2%.
Created benchmark prod in a day (21000BPH line) = 4430002 bottles = 36316 c/s (In entire SAB Miller INDIA)
Remarkable improvement in Quality scores (IQMS) scores both on glass (from 69 to 85%) and can line (from 47 to 85%)
Jump shift in visual labelling performance scores (80 to 93%) and bottle washer performance (91 to 99.98%)
Achieved highest production on can line in a day = 264500 bottles = 11038 cases
Turnaround in the pack hall housekeeping standards.
Hygiene score improvement from 10% to 94%
Innovated and implemented the empty bottle feeding closed loop system.- Unique in beer industry.
Successful formulation and launch of new product projects – Index labelling(PNA), Light weight and ring pull crown changeover, patent, complete bottle label change to new design, changeover of 206 to 202cans, changeover of pet paper labelling to wrap around, Miller High Life, Peroni Nastro Azzurro.
Achieved all time lowest beer loss <0.44%. Reduction from 2.1% to 0.44%.
Stellar performance on sustainable development - Reduction in water consumption from 1.3 to 0.5 HL/HL in packaging deptt.
Efficiently implemented various civil infrastructure improvement projects to completely face-lift the plant
First coach in SABI (Mentor) for grooming the new recruited/positioned Pkg Managers.


AM-Manufacturing/Engineering/TPM
Nov 2005 to May 2007
Company Name : PepsiCo India

Engineering Officer – All India cadre
Apr 2004 to Nov 2005
Company Name : Hindustan Lever Ltd,

Head of Department - Engg
Jun 1995 to Apr 2004
Company Name : Indian Rayon, (AV Birla),

The Accountabilities:
Spearheading the Engineering and manufacturing operations including utilities.
Handling of distillation of fatty acids (distillation and splitting columns) – distilled fatty acid (oil) for soap.
The Attainments:
Merit of having monitored de-bottlenecking product line for capacity and increasing it record new ever highest. (PepsiCo)
Pivotal in escalating the production line efficiency from 91% to 95%. (PepsiCo)
Pivotal role in water reduction across the plant. (PepsiCo)
Benchmarking energy utilisation to best in India esp in utilities. (PepsiCo)
Stellar role in achieving level 2 JIPM TPM award (HLL)
Increase in MTBF and MTTR for Splitting columns (HLL)
Reduction in manpower (HLL).
Power savings in 60 centrifugal pumps (20HP motor replaced by 7.5 HP motors)(IRIL)
Reduction of average breakdown from 10 hrs to 0.38 hours per month (IRIL)
Reduction of departmental expenses from 1.95 lacs per month to 1.1 lacs per month (IRIL)
Continuous reduction in major maintenance expenses by 10% each year. (IRIL)
Reduction of overtime from 120 hour to 68 hours per month (IRIL)
Numerous modifications in plant which has benchmarked department OEE (IRIL)
Implementation of WCM.

Projects handled
High TDS Management project ~ 15Crore
Infrastructure improvement ~ 1.10 crore
Complete renovation of existing tank farm ~ 1.25 crore
Erection and commissioning of BO HE
New waste yarn processing section ~ 4 crores
Additional washing section to increase capacity of plant - 1.0 crore
Complete renovation of existing plant by complete demolition and erection of same

Trainings Attended
Professional:
Advance Problem Solving Skills.
ISO 9000, ISO 14000, ISO 18000, ISO 22000, IMS, TPM, MWay, WCM, OSHAS
Certification course for internal auditor of Integrated Management System (OHSAS 18000, ISO 14000, ISO 9000) by Lloyd’s Register.
Du-point safety course SHE pillar by CII
Non conventional energy resources by Ministry of Non- conventional energy sources
Condition based monitoring systems and RCM by IIPM
Asset management & investment care
Finance for Non Finance Executives.
Lean Management Systems - Kaizen, 5 S.
Seminar on welding technology by L & T, Bombay
Performance Management

Personality Development:
Leadership Development Workshop
Basic Lab on Human Process by Indian Society For Applied Behavioural Science (ISABS)

Apercu
High calibre and result driven manufacturing professional with hands on and accomplished career of 25yrs in food & beverage, brewery, FMCG, and chemicals in Manufacturing, Engineering and Manufacturing excellence including utilities.
Expertise in leading large and mid-size manufacturing and engineering operation demonstrating year on year improvement in PQCDSM with strong and decisive leader capable of managing and fostering excellence in varied industrial climate and change management. Proactive, analytical and achievement oriented professional championing manufacturing excellence philosophy based on TPM, lean, TQM, six sigma and superior performance through effective communication, coordination, strategizing, planning and execution.
Currently associated with JKO as Works Head. Reporting to A.V.P/Sr. GM.
Resourceful in managing overall operations, including Manufacturing, Engineering, Budgeting, and Plant expansion activities with a view to enhance the operational efficiency and capacity utilisation of operations, eliminating obsolescence and achieving cost reduction.
Certified TPM Trainer from CCI, and certified internal ISO 22000 auditor with 23 years of rich experience in Plant Operations, Engineering, Water & Energy Conservation and EHS (Environment, Health and Safety) across industry verticals.
Insightful experience in project management activities encompassing project planning, scheduling, project costing & estimating, finalization of schedules and progress monitoring.
An effective communicator with strong leadership, team management, analytical, troubleshooting and co-ordination skills.
Capacity to work under high pressure situations and motivate team members to deliver desired performance levels. Comfort in relating to people at any level of business & organization for ensuring smooth operations.
Always one of the fast track profile of organization and in the top ranks in the annual performance appraisal system

Future Goals

Aiming for senior level positions viz Head Manufacturing Operations along with Plants Expansion Initiatives, Driving Manufacturing Excellence with a reputed organisation