Plant Operation Head & India Region OPEX Manager - Valmont India (P) Ltd. - Vadodara
(2024-12)
- Coordinating global team for developing and implementing "Lean Methodology" for India region
- Identifying improvement projects for India region with implementation and sustenance tracking
- Training and developing people on Lean tools and techniques
- Tracking key business KPI and Benchmarking performance with global standard
- Daily operation planning including production planning, Manpower planning, Maintenance planning, Raw material availability planning and consumable availability planning
- Driving cost reduction initiative projects at plant level
Manager – Business Excellence & Engineering Projects / CAPEX - Lactalis India Pvt. Ltd. (Sunfresh Agroindustries) - Maharashtra
(2021-11 - 2023-08)
- Support the plant to drive Manufacturing Excellence Initiative to become more cost competitive and effective and embedded the continuous improvement culture at Site
- Lead and manage manufacturing excellence programs for the company. Interact with industry peers and implement programs within the organizations. Also, responsible for managing cost saving initiatives through one's knowledge and expertise
- Leads the Manufacturing Excellence and continuous improvement efforts at Plant in alignment with Plant and Corporate Goals
- Deployment of Corporate initiatives (Lean, TPM / TQM / Six Sigma or other excellence initiative) at site and periodic gap assessment
- Cost Reduction hopper generation, Prioritization and Monitoring at site level
- Leading Business critical project (delivery, quality, efficiency etc.) as assigned at plant to support organization needs
- People development through Training & coaching to ensure smooth execution of OE initiatives
- Benchmarking Best Practices from other plant and deployment - Collaborate with other Plant to maximize benefit realization
- Ensuring efficient use of Operational Excellence communication platforms, continuous improvement meetings, and external sources to build knowledge and cultural change within the site
- Develop and Standardize Systems and Processes
- Takes initiative to generate new ideas within scope of responsibility
- Identifying CAPEX plan for N & N+1 year and generate CAPEX book with all approval
- Implement all CAPEX projects identified for the year
- Track project progress and cost and report to all stake holders periodically
- Report projects saving monthly to record in financial books
- Train and educate on the new system implemented to all stake holders
Management Consultant - Renoir Management Consulting - PAN India
(2021-08 - 2021-11)
- Worked on initial analysis of a integrated manufacturing plant of Skipper limited to identify improvement opportunities
- Worked on ongoing projects of Shyam steels and Energy limited for reducing wastages, improve production efficiency and increase yield
World Class Manufacturing - Facilitator - Saint Gobain India Pvt. Ltd. - Gujarat
(2020-02 - 2021-02)
- Driving 5S of the facility through auditing, coaching / training to employees and resource allocation for driving the journey
- Driving zero accident and injury case related to workplace in partnership with HS pillar
- Delivering business results through WCM projects through identification of projects, defining team and objective, Identifying training requirements and periodic review of progress
- Ensure World class manufacturing pillar are implemented and pillar leaders are delivering the KPI of busines s class results required for WCM bronze journey
- Training of technical staff & employees as required in the approach, task and techniques of WCM and review effectiveness of training, train employees on project methodology of WCM
- Support the management team in the review of progress and the identification and implementation of countermeasures to ensure that WCM programme is achieved
- Ensure communications are fully deployed and answers to questions/points of clarification are auctioned on a timely basis to deliver the required understanding and commitment to WCM
- Takes initiative to keep updated through the WCM intranet portal, as well as through the network of other Group Facilitators, of the latest pillar developments, tools as well as good practices from other plants
- WCM Roadmap development, adherence, and Quarterly review the progress
- Developing WCM resource / people capabilities through training in partnership with People Development pillar
- Plan monthly Gemba walk of senior and middle level management to audit the WCM culture/ standard adherence
- Demonstrated effectiveness of visual aids in the plant, including visualisation tools, SOPs, SMPs, OPL stations etc
- To facilitate monthly pillar meetings and ad-hoc project team meetings
- To facilitate and support in Engineering breakdown meetings, and monthly loss meetings
- To present to the team on an ad-hoc basis latest updates, and to ensure this knowledge is exhibited at the yearly WCM audits
- Analyse losses happening in the plant and identify reactive projects and ensure delivery of projects through teams
- Prepare cost deployment of the plant for the entire year to identify top priority WCM projects for the year to deliver the business results
Consultant (Process Excellence) - PBO Plus Consulting Services - Nashik
(2019-04 - 2020-01)
- Creating project charter for the project, making project plan (WBS) and defining team members deliverables
- Preparing project report and organizing periodic review with client and head quarter for updating the progress
- Successful implementation of 5S in shop floor. Achieved score 56% from 25%
- Reduced setup change over time from 60 minutes to 25 minutes through SMED
- Working on improving overall Yield of the manufacturing facility
- Implemented FIFO in production process
Senior Engineer Manufacturing Excellence (TPM Co-Ordinator) - Advik Hitech Pvt Ltd - Bangalore
(2018-08 - 2019-03)
- Modified factory layout to reduce internal transport time, WIP, operator motion, waiting for material by incorporating cell manufacturing and single piece flow system
- Implemented single piece flow system in Assembly shop
- Implemented Cell manufacturing system in assembly shop to improve assembly shop efficiency
- 5S implementation Training 300 employees in the factory about 5S, preparation of 5S layout with assigning 5S champion, prepared guidelines for 5S and establishing committee for periodic review and feedback for improving the 5S score. Currently achieved 5S score of 85 on average across the plant
- Initiated Poka-yoke journey to achieve defect-free production for all the CTQs with CFT
- Periodic review of OEE, Losses identification and correction against root cause, achieved OEE from 47% to 64%
- Implemented SMED and Reduced cycle time by 40% on average of 6 critical machine
- Organize kaizen competition to keep employees engaged and rewarding / recognizing the best Kaizens monthly
- Identify projects for KK pillar team & debottlenecking the processes
- Enrich & accelerate the growth of TPM culture for Bangalore Manufacturing facilities to achieve ZERO Breakdown, Zero Accident, Zero Defect (3 BADs)
- Responsible for TPM implementation of 8 pillars across all the factory and monitor the same with regular audits
- Execute TPM as per the road map to achieve JIPM excellence award
- Periodically conduct TPM review or measuring the progress and identify scope for improvement
- Responsible for Auditing JH steps after completion
- Facilitate trainings to all the employees on TPM, Lean, 5S and Safety
- To identify training needs related and provide the same with coordination from E&T pillar
- Organize "Success celebration" to improve employee engagement and Morale
- Plan and organize monthly visit of TPM consultant
TPM Officer - Alkraft Thermotechnologies Pvt Ltd - Chennai
(2016-05 - 2018-07)
- Enrich & accelerate the growth of TPM culture for Chennai Manufacturing facilities to achieve ZERO Breakdown, Zero Accident, Zero Defect (3 BADs)
- Responsible for TPM implementation of 8 pillars across all the factory and monitor the same with regular audits
- To plan & execute internal audits and review the NC closure status, conduct TPM review & meeting as planned
- Responsible for Implementing 5S throughout the factory with the help of the steering committee
- To identify training needs related to TPM and provide the same with coordination from E&T pillar
- Responsible for facilitating TPM to all the Circle leaders and Coordinate with all the Pillar heads
- Study the OEE and prepare a loss tree for all the losses and mount the Kaizens/projects for it
- Responsible for making the Capital expenditure budget (CAPEX) for the factory and facilitating of all the CAPEX projects required for the supply chain with timely planned review with top management and all the stakeholders for the project
- Calculate the Factory yielding capacity, Do the line balancing by identifying projects & debottlenecking the processes
Engineer Projects & Safety - Alkraft Thermotechnologies Pvt. Ltd. - Chennai
(2014-05 - 2016-05)
- Responsible for investigating all the Accidents/ Incidents happened in the factory and preparing action plans to overcome them
- Responsible for carrying out Job Safety Analysis (JSA) to identify & eliminate the probable causes based on the risks
- Plan & organize weekly safety review with Safety steering committee and monthly once with all the Top managements
- Prepare the Safety Dashboard for review
- Implementing LOTO (Lockout & Tagout) system in the factory for reducing accidents related to unauthorized access to energy
- Successfully implemented Fire Hydrant system in the factory for fighting with heavy fires
- Implemented Fire alarm system in the factory
- Responsible for execution of all CAPEX projects in the factory
- Prepare Budgets for all the projects, make project plans, organize review with Top management for all the projects & maintain all the necessary documents like funds utilization, Projects updates etc. and circulate to all stakeholders of the project
- Changed factory layout to incorporate single piece flow, Cell manufacturing which resulted in reducing WIP and increased delivery capability (OTIF) for the plant
- Implemented OEE system in the factory and achieved OEE of 72% from 52%
