Abhisek Bhardwaj

Lead the production team from mixing over processing to filling team in accordance with sadafco standards and international best practices to achieve production output in the most cost effective and efficient way.

Delivery of targeted Financial, Service and Quality performance results, through leadership and development of the Management team. Drive the continuous improvement process to achieve gains in efficiency and quality . Co-ordinate with necessary departments regarding safety, expansion, quality, projects and NPD.

Responsible for leading and coaching the Production Plant Team to deliver daily & strategic performance and continuous improvement as part of NFIC Site and contribute to Group Operations, including the day to day leadership of Plant.
 Responsible for Health and Safety standards compliance in the department
 Actively participate in developing and implementing the Site and Department Health and Safety Business Plans
 As a Safety Leader, role model a “Safety First” approach by ensuring all employees, contractors and visitors understand and adhere to the NFIC safety policies, rules and safe work practices
 Ensure H&S performance objectives are assigned to individuals and monitor H&S performance and compliance
 Ensuring Quality standards for the products are met:
 Demonstrate and promote a proactive commitment to product safety and compliance
 Compliance to and maintenance of the Risk Management Plan (RMP) and all elements of this including pest, pathogen, heat treatment (ELLAB), water management and CCP’s
 Compliance to and maintenance of an effective approved HACCP plan, ensure all CCP’s are managed accordingly
 Ensure annual reviews of all quality manuals, RMP & HACCP are completed
 Responsible for business sustainability
 Identify capital projects that provide sustainable revenue or eliminate waste and ensure efficient implementation
 Contribute to the development of the Asset Management Plan
 Ensure wider Plant Team involvement in capital projects to optimize Plant maintainability
 Responsible for improving Productivity
 Ensure the Plant has a detailed loss and waste analysis in place (based on OEE) and structured data-driven and Team-based continuous improvement process
 Ensure efficient and effective operation of all processes within control to achieve Key Performance Indicators (KPIs) in Company Business Plan/Objectives
 Ensure production of the correct specifications of products is achieved on time and in full (DIFOT)
 Responsible for planning People Development
 Maintain locals percentage to enable Business meets its localization program and targets
 Develop effective succession and recruitment plans to ensure a depth of knowledge and leadership within the Plant for seamless transition of key roles
 Foster a learning and sharing culture between Plants, Support Services and other Business units
 Ensuring Employee Performance objectives and development plans are implemented and reviewed quarterly for all direct reports and ensuring training and competency in delivering staff assessments

Manage the plant ensuring production volume targets are met while ensuring that safety, quality, service and cost targets are achieved. Ensure that staffs with the necessary skills are trained and available to run the plant. Drive the continuous improvement process to achieve gains in efficiency and quality. Co-ordinate with necessary departments regarding safety, human resources expansion, quality, new product development

 Ensuring Health and Safety standards are met in the department:
 Ensure Plant H&S programmes are in place and agreed with H&S manager. Agreed H&S audits, risk assessments, H&S initiatives are timely done and within H&S standards.
 Effective Risk assessments are carried out for the complete area and equipments along with timely completion of corrective actions
 Zero accidents
 Ensuring products produced met the required Quality standards:
 Ensuring right first time release of the product
 Ensuring zero dumped material
 Targeting zero tolerance for the non conformance product and Less than budgeted CPM
 Maintaining AIBI score >850
 Ensuring meeting the Customer demand:
 Monitor stock levels daily/weekly to ensure market is supplied but not over stocked
 Ensuring Customer service agreement (CSA) target is achieved
 Understanding of potential market sales verses capacity and address capacity constraints to meet the demand
 Optimize production plan to improve OEE and deliver production plan requirements
 Actively involved in implementation of lean management initiatives to arrest the Cost:
 Ensuring LIP for ingredients, packaging well under budget as well as labor cost under control
 Carry out loss and waste analysis, identify top improvement projects and implement
 Identify and address top LIP issues using structured problem solving tools
 Ensure that budget is achieved and reduction of LIP and rejections is put to a minimal thus achieving consistent product yield optimization ultimately minimizing production cost.
 Leading the effective utilization of tools to enhance Productivity
 Productivity Improvements using Structured problem solving approach.
 Put in place plan to progressively increase OEE by 5% every year
 Leading the People Development plan within the department
 Hold effective induction programmes for all new starts
 Introduce daily line meeting with operatives to review line performance and nurture engagement
 Draw up and implement an effective localization programme to deliver company targets
 Ensure coordination with Training & Development of staff is done ensuring need analyses are carried out and ITP’s are executed promptly in accordance to training calendar.

Coordinate, facilitate and drive operational excellence initiatives in line with the Business manufacturing strategy
 Leading implementation of Lean Management initiatives
 Leading the Loss and Waste exercise in order to identify the waste in the process, carrying out speed profile study to identify bottlenecks, value the opportunities followed by prioritizing and action plan to reduce the losses
 Key representative for implementing Target savings activities
 Leading CIP optimization activities viz CIP time reduction, CIP regime optimization, chemical conc. reduction
 Implementation and review of process confirmation checklist and control charts in order to have more focus on the operation by the manufacturing team
 Leading drain losses reduction projects in order to reduce the waste in drain
 Responsible for optimizing the process as well as increase in the current production volume by optimizing the production plan
 Implemented Structured problem solving exercise using 5 whys, 5S, DMAIC, PDCA, SUTR and A3 so that the root cause is identified and proper corrective and preventive action implemented in place
 Assisting production Managers in developing and reviewing pictorial SOPs
 Analyze the need and purpose of each production set point responsible for driving the process line and drawing out the optimum requirement
 Continually update the process and planning constraints and challenging continually for getting maximum benefits
 Creation of cause-effect library for process related issues for supporting production, quality, engineering and other related departments towards quickly solving the product-process issues
 Implement "Key performance indicators" monitoring chart for each line to monitor critical production parameters against the standards/limits
 Dealing with suppliers to get the technical inputs for process and CIP
 Optimization of the production parameters to have consistent quality products produced across all production lines
 Optimization of ingredient usage to have efficient use of ingredients towards achieving targeted specifications
 Preparation and maintenance of guiding rules for production planning, processing and cleaning conditions
 Implemented the concept of Customer service agreement (CSA) in the plant
 Coordinating with cross functional team viz production, quality, TRD, CIT to develop the process standards

Facilitate and direct production teams to efficiently process commodity dairy products to meet internal customer order requirements within management performance parameters ensuring adherence to defined Product Specifications, Quality and Safety Standards.

 Management of new/improvement projects towards timely, effective and efficient implementation and commissioning of equipment / process and product
 Active involvement in installation and commissioning of new machines and process
 Preparation of Project briefing document for improving the existing process and product as well as for expansion
 Involved in HARA (Hazard analysis and Risk assessment) for the project
 Leading the Project installation and commissioning activities
 Coordination with the other department during installation and commissioning
 Responsible for successful completion of product trials and commercial production on the new equipment ensuring no snag pending at the end of the project
 Responsible for facilitating SOPs related to the project and in turn ensuring training of the production staff and operators
 Managing the implementation of new equipment and process through validation programs
 Working with Continual Improvement team for product NCN’s, product complaints, root cause investigations and corrective actions
 Ensuring corrective actions are implemented and measures are incorporated into quality system to prevent recurrence and Working towards zero product on hold status in DQR
 Ensuing the adherence to procedures through audits and updating SOPs whenever necessary.
 Key member of HACCP team; Involve in HACCP study of all cheese products and services
 Certified AIBI Auditor and Internal ISO auditor
 Ensuring no impact on product quality post CIP optimization
 Managing Control / Ensuring hassle free operation of UHT plant, vacutherms, Corazza, Trepko, Weigh pack jar filling and FMC can filling lines

 Conducting trainings for key operators for process optimization
 Validation of the P&I diagrams and process design
 Study and validate PID
 CIP validation
 Follow up of hardware and software related project snags
 Participate in the control and minimize wastage of materials, product, consumables and chemicals to achieve budgeted targets
 Improvement in ingredient LIPs to targeted levels
 All blending batch meeting targeted requirements

 Involve in the commissioning of new projects
 Conduct training for the operators during commissioning
 Liase with process team manager and CIT for investigations of non conformance and identifying the
corrective and preventive actions
 Assist manufacturing team in continuous improvement and problem solving
 Prepare and maintain proper document compliance

 Commission of new equipments by I/O checks, water and product trials
 Conduct process and CIP validation of new equipment
 Involve in online troubleshooting by identifying the exact root cause
 Maintain Health and safety objectives

 Ensuring staff management
 Maximizing utilization of available resources
 Ensuring health and safety requirements are met
Zero accidents within the department
 Ensuring area meets all quality requirements
 Training for the production team
 Process trouble shooting
 Maintain record keeping as per the standard operating procedures