Factory Manager - SP Concare Pvt. Ltd. - Sangli, MH
(2025-11 - 2026-04)
Directed absolute, autonomous operational and functional accountability for a state-of-the-art Construction Chemicals manufacturing establishment. Orchestrated cross-functional divisions encompassing production engineering, scheduling, inventory control, maintenance engineering, and strategic dispatch logistics.
- Leveraged Enterprise Resource Planning (ERP) PP and MM workflows to drive material requirements planning, reducing stock-outs and streamlining operational throughput.
- Enforced comprehensive compliance maps aligning plant activities with statutory pollution boards, safety inspectors, and international ISO standardizations.
- Spearheaded localized plant safety cultural modernizations by creating, framing, and conducting training modules for 5S frameworks, Root Cause Corrective Actions (CAPA), and Lockout-Tagout (LOTO) safety protocols.
- Designed and mandated high-risk operational standards by rolling out automated Safety Work Permits alongside strict adherence to Good Manufacturing Practices (GMP).
Assistant Manager – Manufacturing & Production Planning - DSM-Firmenich Pvt. Ltd. - Mumbai, India
(2013-03 - 2025-07)
Commanded production planning, tactical scheduling, and lean floor-level execution for a premium, high-complexity Fragrance and Specialty Chemical processing plant.
- Kinaxis Rapid Response User for Demand and Supply and Planning.
- Manage raw material replenishment and inventory levels by defining reorder quantities, frequencies, and maintaining alignment with the overall supply chain inventory strategy.
- Monitor supplier performance and compliance, addressing issues such as delays, damages, shortages, and deviations while maintaining high purchasing data quality.
- Drive continuous improvement in sourcing and supply processes by coordinating activities across purchasing, quality, logistics, procurement, suppliers, and warehouse teams.
- Maintain and execute the supply plan (Buy & Transfer), ensuring visibility of incoming and outgoing supply flows and supporting an efficient Plan–Source–Make–Deliver cycle.
- Supplier non-conformances and supply risks through structured follow-ups, root cause analysis, CAPA implementation, and collaboration with procurement to strengthen vendor partnerships.
- Spearheaded strategic continuous improvement (CI) initiatives, reducing regional inbound and outbound transportation costs by restructuring Raw Material (RM) sourcing maps and coordinating collaborative inter-plant distribution networks.
- Established a data-driven operational baseline by rigorously tracking critical production KPIs, including On-Time Delivery Rate (OTDR), On-Time Delivery In Full (OTIF), material process Yield, batch cycle time tracking, and Overall Equipment Effectiveness (OEE).
- Champions Process Safety Management (PSM) and workplace EHS by leading formal Risk Analysis and Hazard and Operability (HAZOP) studies, establishing rigorous near-miss tracking loops, and sustaining zero-incident plant safe operations.
- Engineered comprehensive resource sustainability matrices to monitor and curb environmental footprint, strictly tracking utility matrices for water consumption, electricity usage, and steam efficiency.
- Instituted rigorous Quality Assurance frameworks to map product parameters, drive root-cause investigations into customer complaints, and implement structural process correctives.
- Structured dynamic workforce utilization charts, led mid-scale people management programs, and executed rigorous multi-shift scheduling to secure continuity of automated continuous-process configurations.
- Synthesized high-impact cross-functional coordination frameworks tying together plant operations, integrated supply chain, strategic global procurement, corporate finance, B2B sales, and quality assurance.
Shift In-Charge - Apar Industries Pvt. Ltd. - Rabale, Navi Mumbai
(2010-02 - 2013-03)
Supervised complete operational shifts for a high-volume process facility manufacturing Lube Oils, White Oils, Automotive Oils, and Transformer Oils, managing end-to-end batch processes.
- Commanded core Lubricant Blending operations, orchestrating the precise integration of Base Oils (Group I, II, and III) with performance chemical additives through Automated Batch Blending (ABB) and In-Line Blending (ILB) systems.
- Optimized critical formulation metrics by closely monitoring process parameters like Blend Homogeneity, Viscosity Index (VI), Total Acid Number (TAN), and Flash Point to ensure conformance to strict automotive and industrial lubrication specifications.
- Enforced tight controls over additive dosing, optimizing the dispersal of Viscosity Index Improvers (VII), anti-wear agents, pour-point depressants, and detergents while eliminating product cross-contamination risks during multi-grade product transitions.
- Executed localized short-term production planning maps, deploying lean principles to resolve real-time bottlenecking variables across automated blending manifolds and high-speed filling/packaging networks.
- Leveraged SAP PP modules to validate material consumption metrics, execute comprehensive shift handovers, register precise production yields, and minimize process-to-system data latencies.
- Maintained rigorous compliance safety protocols, conducting safety risk assessments, shift safety stand-downs, and executing ISO 9001/14001/45001 procedural compliance frameworks to preserve plant structural stability.
Shift In-Charge - Dow Corning India Ltd. - Ranjangaon, Pune
(2003-12 - 2010-01)
Commanded batch manufacturing of high-performance silicone sealants, chemical emulsions, and advanced dispersions under rigorous cGMP benchmarks and global EHS safety guidelines.
- Directed the compounding of Lithium Complex Greases, High-Pressure (HP) Greases, and Specialty Silicone Greases utilizing Three-Roller Milling technologies to ensure uniform raw material dispersion and controlled rheology.
- Regulated critical recipe-level parameters including shear rate, process temperature profiles, vacuum levels, curing cycles, and multi-filler ratios to protect product structural and chemical uniformity.
- Oversaw daily material requisition maps, lean bulk material transit pathways, and outbound vehicle logistics while balancing material transport constraints.
- Governed operational SAP PP transactional loops, scheduling equipment run-times, tracking material allocations, and recording equipment downtime to maximize Production.
- Appointed and served as Site Incident Controller (SIC) during emergency drills and mock scenarios, driving unified crisis command architectures until regional emergency rescue arrivals.
- Participated as a key auditor in global internal EHS safety verification audits, driving shop-floor hazard identifications, near-miss reporting systems, and structured housekeeping (5S) protocols.
Production Supervisor - Reliance Silicones Pvt. Ltd. - Kopar Khairane, Navi Mumbai
(1998-10 - 2003-11)
Controlled shifts for an advanced, highly hazardous silicone oil manufacturing plant, safeguarding continuous operational stability and output quality.
- Maintained physical operation and rigorous monitoring of critical chemical process hardware, including fractional distillation columns, high-pressure glass-lined chemical reactors, heat exchangers, and bulk storage networks.
- Supervised multi-stream raw material charging profiles and tracked mass balance calculations across exothermic synthesis cycles to eliminate thermal runaways.
- Drove shop-floor process standardization initiatives to improve cycle-time efficiencies.
- Enforced comprehensive corporate ISO compliance and strict statutory environmental control requirements, managing effluent treatment plant (ETP) delivery metrics on the shop floor.
- Coordinated structured daily shift handovers and technical log-sheet audits, optimizing communication loops and resource readiness across cross-functional shop floor teams.
