Production Manager
Akshayakalpa Farms and Foods Pvt Ltd.
Total years of experience :3 years, 8 Months
• Conduct capacity planning, Executing, and reviewing the agreed production plan to meet daily/weekly/monthly sales
and operational targets.
Asst. Manager, Milk Balance, Almarai Company, 12/2020 to 02/2022
Production Shift Manager, Glanbia Cheese EU, 04/2022 to 11/2022
• Ensure efficiencies of man, machine, and material resources to meet the desired targets. Shift scheduling and its
compliance, effective usage, and optimized allocation of manpower for production.
• Ensure production team members adhered to QA protocols strictly and bridge effective communication between QA,
production, and dispatches for timely clearance.
• Monitoring of RMPM yields on daily basis and root cause analysis for the lapses and fix the process steps that cause
material loses.
• Accountable for GMP and GHP across the site.
• Proactively lead in fixing up market feedbacks and sharing corrective action and preventive action reports by
coordinating with QA and maintenance teams and share action taken proofs to the management.
• Co-ordinating market and field visits to understand the routine issues and initiating appropriate corrective actions to the
factory.
• Co-ordinate with R&D, QA, Market Teams for new product development trials and commercial launches.
• Daily MIS and work towards cost optimization.
• Schedule In-house training of existing employees, new joiners, and fresh manpower recruitment.
• Monitoring RMPM material inventory and maintaining seamless communication with supportive cross functions such that
production activities are smooth and uninterrupted.
• Waste disposal management and co-ordination with cross functions.
• Asset management and accountable for the domain
Involved in the commissioning of PTS-19 - “Bosch Filler”, new of its kind in Almarai CPP-1.
* Involved in the commissioning of CPP-1 New dessert Storage Tanks.
* Involved in “utility data collections and report preparations” for the upcoming new plant
CPP-4.
* Involved in SOP writing in CPP1 processing.
* Involved in installation and commissioning of “CPP-3”, a highly automated plant of Almarai,
processing around 2M Ltrs of milk every day.
INSTALLATION & COMMISSIONING OF CPP-3:
* Study of business requirements for the new plant and preparing scope for the project.
* Detail study of Supplier’s process descriptions and P&ID’s and meeting supplier every day
for reviewing.
* Involved in Pre-FAT (Factory Analytical Test) of CPP3.
* Involved in issuance of PTW (Permit to Work) in order to maintain the Safety protocols of the
company always.
* Involved in installation activities of CPP3 from Milk intake to Milk storage tanks after
processing.
* Welding checks using “Endoscope” along with GEA for effective welding of Pipe lines
* Preparing report for the endoscopy pics by identifying the welding defects which may
potentially cause FB risks online and circulating to team and supplier for re-work.
* Preparing “weekly progress presentations and Meeting minutes”, which compares the
weekly installation and commissioning against plan and to push supplier for on time
completion of project.
* Coordinating with different contracts on site for effective and efficient installation.
* Coordinating CPP-3 DT’s team for their work assignments, daily activities, transportation,
and academic related works
Trained and worked in Milk intake, Main mixing, Dessert mixing, operation of
pasteurizers (Laban and Zabadi).
* Operation of automated dairy equipment’s for processing of milk & milk products.
* Handled floor level operations from milk intake to final processing of milk & various milk
products in Almarai- CPP1.
* Responsible for process plan achievement in shift wise activities.
* Planning the process activities Pre and Post shutdown activities for running the plant
successfully after shutdown.
* Achieve the plan and releasing the products on time for the filling departments, by ensuring
all the released products meets Almarai quality standard.
* Responsible for trouble-shooting day to day process & quality related problems and process
optimization using 5WHY and FISHBONE methods.
* Effective planning of the products & process equipment’s to maximize run length and
minimizing the product loss.
* Managing multitask workforce through allocating responsibilities based on skill level and
improving skill levels of manpower through timely trainings in coordination with superiors and
peers
* To provide on job training to Operators.
* Assessment of operators against safety monthly briefs and tool box communications.
* Scheduling & releasing the process equipment for preventive maintenance & breakdown
maintenance in coordination Engineering & planning team.
* Troubleshooting of processing issues, investigating the product related deviation and
implementing corrective & preventive actions.
* Commissioning of new equipment and factory acceptance tests.
* Conducting safety audits and periodical risk assessments within the department to
ensure necessary safety working standards are met.
* Investigation of product non-conformities and process related issues and assisting other
departments for the same and implementation of necessary corrective actions.
* Developed periodical GMP tool box schedule for all department employees aimed at
enhancing the GMP awareness and adherence to highest possible GMP standards.
* Managing of departmental and plant activities in absence of superior.
* Conduct tool box talk to the process employees to fill the gaps of process deviations.
* Responsible for planning and conducting 5 S, GMP and inter department AIB audits.
* Updating SOP’s, ensuring all activities is carried out in accordance with SOP specified in the
Quality System.
* Review and update of SOP based on Quality audits, Health & safety and new
developments.
* Managing K-Milk and K-cream requirements during Ramadan season.
* Coordinating the projects activities with project team and fixing the snags during
production.
* Optimizing the mixing tank plans and mixing batches as a shift in charge.
* Manpower management on shift basis with respect to allocation of jobs to operators,
scheduling weekly holiday and vacation, and arranging necessary trainings for all staff.
Production planning & management.
* Effective utilization of manpower.
* Was responsible in handling 45 people per shift including the office staff
* Providing resources required for individual departments
* On time dispatch of UHT milk as per requirements
* Co-ordination with different raw materials suppliers (Filling and packaging materials)
* Co-ordination with “Tetra-pak” team for PM’s and weekly checks
* Quality & productivity management
* Stock keeping
* Maintenance of different records related to the plant
* Maintaining clean and hygienic environment in production area as well as surroundings
* Ensure team work in all respects of controlling the waste in time, packaging & products
* Responsible for calibration of all equipment and instruments
* Performance management
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