Prashant Rao

Result-driven Production and Operations Manager with over 14 years of experience driving exceptional efficiency, cost reductions, and operational excellence in high-volume manufacturing environments. Expert in Lean Six Sigma methodologies, workflow optimization, and strict safety compliance (HACCP, GMP). Proven track record of spearheading multi-site plant consolidations, scaling production capacities up to 92%, and lowering waste metrics by 70% while leading and mentoring high-performing on-site and remote teams.

Production & Operations Manager - Bolo Create Inc. - Mississauga, ON

(2024-05 - 2026-07)

• Directed end-to-end production planning, complex scheduling, and daily operations in a high-volume print manufacturing facility, successfully ensuring 100% on-time delivery and alignment with corporate quality standards.
• Coordinated strategic vendor relationships and material requirements planning to eliminate logistics bottlenecks and achieve consistent, dependable fulfillment timelines.
• Optimized operational workflows to improve overall facility efficiency by over 20%, significantly mitigating costly equipment downtime and material scrap.
• Designed and executed a structured modern proofing system that reduced production rework, enhanced output accuracy, and raised client satisfaction metrics.
• Accelerated monthly recurring revenue by 30% by partnering with key stakeholders on tactical B2B client acquisition initiatives and value-driven pricing structures.
• Pioneered the integration of modern AI tools to streamline production reporting, seasonal forecasting models, and automated inter-departmental communication processes.

Production Manager - LEC Custom Products Ltd. - Brampton, ON

(2020-01 - 2024-05)

• Orchestrated the high-stakes 'D2K' plant consolidation project, seamlessly merging 3 separate production facilities into 1 centralized plant with zero operational downtime.
• Managed the safe installation, calibration, and launch of major new production and automated packaging lines, exponentially increasing long-term output capacity.
• Drove plant-wide production efficiency from a baseline of 70% up to an optimal 92%, resulting in substantial reductions in unnecessary labor costs and overtime expenditures.
• Overhauled batch scheduling protocols and integrated inventory management tools to strictly minimize material waste and streamline manufacturing transitions.
• Developed, coached, and mentored 7 frontline operational leaders, cultivating a sustainable culture of safety, accountability, and continuous improvement (Kaizen).

Production Supervisor - Weston Foods Ltd. - Brampton, ON

(2014-09 - 2019-12)

• Reduced raw material and product waste from 13% down to an industry-leading 4% through targeted continuous improvement initiatives and Lean methodologies.
• Coordinated master shift schedules, conducted meticulous annual performance reviews, and supervised daily floor operations to guarantee smooth, uninterrupted workflow.
• Directly managed and supported a diverse workforce of 50+ hourly employees across both the high-speed production lines and automated packaging departments.
• Elevated cross-shift team engagement and safety compliance by designing and implementing structured floor communication initiatives.

Production Supervisor - Handi Foods Ltd. - Etobicoke, ON

(2007-03 - 2014-09)

• Led cross-functional continuous improvement teams that targeted systemic line bottlenecks, successfully streamlining workflows and boosting plant efficiency.
• Expanded total manufacturing capacity by 45% through the strategic planning, layout configuration, and execution of new manufacturing line installations.
• Spearheaded the design and deployment of an advanced production reporting module within Microsoft Dynamics, delivering real-time, data-driven insights to executive decision-makers.
• Maintained flawless compliance records with HACCP, GMP, and corporate safety regulations to safeguard product quality, pass external audits, and mitigate operational risks.

Master of Science - Computer Science - KCC Institute of Technology & Management

Bachelor of Science - Commerce - The Maharaja Sayajirao University of Baroda