Murali. N

Certified JIPM TPM Facilitator & Six Sigma Green Belt Professional offering over 20 years of experience in running successful method-oriented operations and taking initiatives for business excellence through process improvement across Food & Engineering domains. Rich experience in enhancing the production process operations, optimising resource & capacity utilisation and augmenting productivity & operational efficiencies while curtailing costs & expenses. Resourceful in analysing prevalent production systems / processes, identifying loopholes, if any and undertaking result-oriented measures for alleviating and documenting the same.

Hands-on experience in planning & implementing the preventive, predictive & breakdown maintenance schedules for improving overall reliability and safety of plant equipment & machinery. Excellence in implementing Quality Management Systems like TPM, DuPont Safety, HACCP & Operational Excellence for Quality Improvement. Improved the mechanical efficiency by 20% through implementation of OE methodology (DMAIC Process Approach).

Reduced the laminate wastage from 3% to 1.5% through introduction of laminate end roll joining practice. Excellence in formulating MIS reports for cost savings / quality assurance & transmitting to top management. Efficient organizer, motivator, team player and a decisive leader with the skills to motivate teams to excel & win.

AGM Manufacturing & Operations - RNGALLA FAMILY PVT LTD., (GALLA FOODS), An Amaraja Group Company - Chittoor

(2022-07)

Spearheading a team of 300 technical personnel; managing shift operations, maintenance scheduling, daily production planning, RM & PM and capacity planning. Executing & monitoring daily plan in all shifts to achieve the production & system line efficiency and yields. Engaged in production planning & resource planning of Pulp Plant and beverage plant.

Contributed in facilitating maintenance, operations and troubleshooting. Monitoring & controlling wastages in Process, packing and other areas. Implementing TPM, inventory management, work scheduling and cost control.

Administering visioning activities cost-effective programs execution. Performing systems audits at various plant departments. Creating, implementing & updating standard operating procedures. Identifying critical areas of obstruction / breakdowns and taking steps to rectify the equipment through application of troubleshooting tools.

Coordinating with internal customers to meet production-oriented requirements. Ascertaining the entire in-process quality control & continuous improvement in line capabilities, foreseeing performance bottlenecks and taking corrective measures to avoid the same. Imparting job training to the wor

• New 300 BPM Beveage Hot Fill line Project implementation from Conceptualization, Budget Preperation, Supplier Finalization, Statutory compliances, Installation and Commissioning, Team members recruitment, Training, Validation etc.
• Improved plant's SKU Compliance from 74% to 89%.
• Beverage Yield improved from 96% to 98.7% through DMAIC approach.
• Used Time Motion Study for optimization of manpower, which resulted in optimizing 12 Manpower per day
• Implemented Crate Washing machine with a capacity of 1000 Crates/hour for Pulp Plant
• Implemented "Ethylene Gas generation system" in ripening chambers to improve the Pulp yield and optimize the fruit wastages.
• Prepared the plant and Cleared Coca-Cola GAO Audit for the plant in QSE Module in the first attempt with no Major deviations.

Senior Manager – Operational Excellence - VNF Ideas Pvt ltd (FRAAZO) - Mumbai

(2021-10 - 2022-07)

Prepare Operational Excellence stratregy and Master plan for the Pan India operations and execute the same for all collection Centres and Dark stores.

Drive Operational

Excellence and Quality improvement initiatives. Optimization of resources like wastage at all levels. Productivity enhancement and Availability improvement through innovative ideas implementation at all stages. Customer complaints analysis and optimization to improve the customer experience.

Training

Calendar and execution at all levels on Operational Excellence and Quality Assurance methodologies. Budget preparation and cost control of QA and Operational Excellence.

Senior Manager – Production - Perfetti VanMelle India Ltd. - Chennai

(2016-08 - 2019-03)

Spearheading a team of 400 technical personnel; managing shift operations, maintenance scheduling, daily production planning, RM & PM and capacity planning. Executing & monitoring daily plan in all shifts to achieve the production & system line efficiency and yields. Engaged in production planning & resource planning of beverage and packaging units.

Contributed in facilitating maintenance, operations and troubleshooting. Monitoring & controlling wastages in Process, packing and other areas. Implementing TPM, inventory management, work scheduling and cost control.

Administering visioning activities cost-effective programs execution. Performing systems audits at various plant departments. Creating, implementing & updating standard operating procedures. Identifying critical areas of obstruction / breakdowns and taking steps to rectify the equipment through application of troubleshooting tools.

Coordinating with internal customers to meet production-oriented requirements. Ascertaining the entire in-process quality control & continuous improvement in line capabilities, foreseeing performance bottlenecks and taking corrective measures to avoid the same. Imparting job training to the work

• Administered new line installations like Extruded Jelly, 3 Layered Gum, Happydent Wave, Centre Fresh Soft Chews, and so on
• Improved plant's SKU Compliance from 84% to 98% and volume compliance from 85% to 99%
• Used Time Motion Study for optimization of manpower, which resulted in optimizing 88 Manpower per day
• Worked on SMED/ECRS Method and optimized change over time by 65% on POP packing machines
• Implemented DMAIC & Minor Stoppage Mapping methodologies for optimizing the reject generation and optimized the reject from 29% to 10% on POP line and from 79% to 16% on 3LG line and from 28% to 13% on EJ line, etc.
• Recognized for increasing plant efficiency from 74% to 89% through effective maintenance and RCA CAPA implementation for down times; was appreciated for same

Associate Head – Production - Perfetti VanMelle India Ltd. - Chennai

(2019-04 - 2021-07)

Spearheading a team of 400 technical personnel; managing shift operations, maintenance scheduling, daily production planning, RM & PM and capacity planning. Executing & monitoring daily plan in all shifts to achieve the production & system line efficiency and yields. Engaged in production planning & resource planning of beverage and packaging units.

Contributed in facilitating maintenance, operations and troubleshooting. Monitoring & controlling wastages in Process, packing and other areas. Implementing TPM, inventory management, work scheduling and cost control.

Administering visioning activities cost-effective programs execution. Performing systems audits at various plant departments. Creating, implementing & updating standard operating procedures. Identifying critical areas of obstruction / breakdowns and taking steps to rectify the equipment through application of troubleshooting tools.

Coordinating with internal customers to meet production-oriented requirements. Ascertaining the entire in-process quality control & continuous improvement in line capabilities, foreseeing performance bottlenecks and taking corrective measures to avoid the same. Imparting job training to the work

Team Lead – Production - Hindustan Coca Cola Beverages Pvt. Ltd. - Moula Ali (Hyderabad) and Bidadi (Bengaluru)

(2010-09 - 2012-12)

• Managed new equipment installations like ASEBI & Tilt Conveyor and wrote & implemented SOPs
• Worked on projects related to Wastage Optimization, NVA Elimination, Cost Optimization, SMED for Change Over Time Reduction, Bottleneck Elimination, Work Simplification and Safety
• Resolved 5 chronic issues on line by using TPM advanced tools like WWBLA, FMEA & PM Analysis
• Completed quality projects within time by taking quality maintenance pillar initiatives and reduced the plant customer complaints by 55% over previous year
• Facilitated preventive maintenance planning & execution through CMMS System and SAP PM Module
• Spearheaded team for achieving most covetous 'JIPM TPM Excellence Award' from JIPM Japan in 2013
• Conferred with Best Circle Award in 5S & JH Implementation in the plant
• Received Best Kaizen Award from CII-TPM Club of India at All India Level Kaizen Competition in 2013 & 2014

Manufacturing Excellence Manager (TPM Manager) - Hindustan Coca Cola Beverages Pvt. Ltd. - Moula Ali (Hyderabad) and Bidadi (Bengaluru)

(2013-01 - 2016-08)

Senior Production Executive - Hindustan Unilever Ltd. - Dharwad & Silvassa

(2006-04 - 2010-08)

• Implemented Autonomous maintenance activities and continual focus on improvement of OEE
• Steered efforts in implementing 5S & JH and TPM within the organization
• Pivotal role in training and making employees aware about TPM & Kaizens to be implemented on shop floor
• Improved FFS Packaging Machines OEE from 85% to 91% and BBOEE from 35 % to 41% through implementation of TPM Tools such as RCA, WWBLA & FMEA
• Revamped PFS machine from 10 funnel operations to single funnel operations; improved the output and reliability of machine

Asst. Production Engineer - Kitchen Grace India Pvt. Ltd. - Pune

(2003-04 - 2006-03)

• Operating and Maintenance of CNC Routing, CNC Band saw, CNC edging and CNC sanding machines.
• Documentation of daily, weekly and monthly maintenance checklist of respective machines.
• Maintaining GMP & GHK practices. Production planning, Raw material and consumable procurement.
• Shift Operations and production scheduling.
• Conducting awareness programs and Refresher Courses on GMP & GHK, Safety.
• Monitor & control on all process Quality parameters.
• Learning and motivating sub-ordinates towards new systems and changes, which are being done to control inventory and for plant development.