Rushikesh Kardule

Chemical Process Engineer with 3 years of experience in surfactants manufacturing industry across batch and continuous process plants, specializing in Process Optimization, Safety Improvement, Cost Efficiency Projects, Energy Management & Automation. Expertise in driving operational excellence through debottlenecking, TPM initiatives, process safety improvements and implementation of practical manufacturing solutions to improve process efficiency, operational reliability and overall plant performance.

Executive at GALAXY SURFACTANTS LIMITED (2023-07 – Present)

• Led Cost Efficiency Projects (CEP) delivering organizational savings of ₹2.5 Cr annually through process improvements, debottlenecking initiatives, utility optimization and waste reduction across manufacturing operations
• Led process safety improvement projects involving elimination of manual handling of Class A chemicals such as DMAPA, MEA, H₂O₂, Acetic Acid, Sodium Methoxide & MCA through automation, closed-loop systems and engineering controls to enhance operational safety and reduce risk exposure
• Experienced in project scheduling, calculations & validations, layout/P&ID/PFD, vendor development, procurement planning, technical bid analysis, cost estimation for project execution & site management
• Led digitization and automation initiatives including eBMR, digital checklists and Recipe Management for batch processes, reducing checklist filling time by 30% and improving process tracking and data visibility
• Knowledgeable in 14 Elements of Process Safety Management & a trained professional for conducting PHA/HAZOP studies, PSSR & risk assessment through AI-HIRA
• Well-versed & experienced in best-in-class industrial techniques like Why-Why-Analysis, Root Cause Analysis, 4M Module, QM & DOE to build robust system & ensure 100% reliability with maximum uptime
• Performed monthly Power, Fuel, Steam, & SVCOI variance analysis involving utility optimization, energy tracking and budgeting accuracy improvement
• Collaborated with Instrumentation, Maintenance, Quality, RMU, Safety & Production teams for execution of automation, utility optimization and process improvement projects
• Played key role in TPM implementation initiatives including JH Step audits, Process Point Analysis (PPA), Kaizens, OPL development while contributing in TPM special award audits

Bachelor of Technology in Chemical Engineering – Laxminarayan Institute of Technology (2023-06)

HSC – Atma Malik International School (2019-06)

SSC – Vikhe Patil Sainik School (2017-06)