QUALITY ASURANCE MANAGER
MULTIPAC LTD
Total years of experience :43 years, 0 Months
Quality head for all beverage, Juice, water, CSD, Hot fill, Cold fill, Malt related activities.
In-charge of Quality Assurance .Implementation of Nestle Standards across the system.
reason for leaving: unsafe security reasons.
Manager (Quality Assurance)- Parle International Pvt. Ltd (A unit Of Parle Agro) Mumbai
Heading the largest unit of Parle Group of companies plant at Mumbai. This is the flag ship company of Parle Agro , Brand leaders of Frooti, Appy Fizz, frooti Tetrapack, Frooti Hot fill, Café Cuba, Bailley (packaged Drinking water) etc.
The plant is having 3 lines of TBA- 19, 2 lines of TCA-90 ml, hot fill and Aseptic filling lines.
Job Responsibility
In charge of Quality Assurance, Implementation of PAPL standards across the system,
Overseeing Export Quality systems, Certification Audits like BRC, Halal, ISO 22000:2005, EIC, Kosher, SQF etc implementation. Beverage yields, WUR, Sugar Yields, CGMP, Consumer concerns attendance.
Coordinating with Exports Division for export of our Products (exporting to countries like USA, UK, Gulf, Africa, Europe etc.). Conducting internal compliance audits of all the standards and follow ups
Conducting employees training programs on Standards Achieving objectives like Quality Index, conc. yield, CO2 yield and sugar yield .Commissioning of Hot Fill Line from Erection, Commissioning, Sterility Trail and commercial production. Independently upgraded the WTP-Coagulation Plant Set up. Up gradation of Process Area-Tetra & Hot Fill Line production. Commissioning of Juice Based CSD Line from Erection, Commissioning, Sterility Trail and Commercial production.
Achievements
Zero Product Recall
Reduction of consumer Complaints
Increase in Sugar Yield by 1.5%
Beverage increase by 2.2%
Wastage of laminates /Cartons Reductions by implementing Strict Quality Control standards
Zero Down Time due to non availability of Water / beverage.
Improved and upgraded the Plant to Top position among the Parle’s Six Plants
Corporate Quality In charge for Aseptic Pulp divisions ( 6 plants), IQF(Individually Quick Frozen Fruits), RTE ( Ready to Eat ) Food products, Aquafina ( Pepsi Bottled water).
Ensuring BRC, FSMS, SGP, HALAL, KOSHER etc Audits Compliance .
Supplier audits
Overall Quality Assurance
2.GM- Quality Assurance VARUN Beverages (Pepsi Franchise) RJ corp. Sept.1999 - to 2013(Feb.) Bhiwadi & Sonarpur ( Kolkata)
One of The biggest Pepsi bottling plant) having 6 lines CAN LINE(1), PET(1), GRB(2), AQAUFINA(packaged Drinking water), (1)JUICE LINE GRB &PET(HOT FILL ) (1 with capacity up to 2400 BPM. 120, 000 cases per day production capacity. (6 lines) and AOP is above 20 Million cases.
Job Role: Quality Assurance of all the aspects of Pepsi system. Syrup Making, Water Treatment, Batch making and finalisation, Microbiological evaluation of the Products, R.M/P.M checking, etc. Tracking vital operational data known as “ key performance indicators” like 3D quality, plant Quality, Food safety, Trade Quality, sensory, Micro, Physio, packaging Appearance, Product integrity as per Pepsi Standards, , Managing all the documentation, ISO 22, 000, ISO 14000, AIB (THIRD PARTY UN ANOUNCED AUDITS ON FOOD SAFETY SYSYTEMS
AIBI Audits, QMS implementation, , water consumption &Water Recovery, M&W implementation, , Total Plant waste ( mainly sugar/ concentrate raw material and packing material losses, ) productivity, .Conducting daily, weekly Quality review meetings with teams covering Quality related issues. Handling of market complaints
Execution various new projects in the factory related to product safety, new SKU’s, quality improvement and cost saving projects. And water conservation methods /implementing recovery systems with an objective of “Zero discharge”. Providing technical guidance to the vendor team, guiding them on resolving performance bottlenecks. Implementing HACCP, AIBI, ISO22000, IS014000 Safety Systems to prevent contamination in the food processing chain.
Achievements:
Facilitated the implementation of the Pepsi Quality Plan in letter and spirit.
Integrated system of ISO 22000 -2005 & ISO 14001 -2004 implementation and audits
A. concentrate yield saving : 2010: 25 lacs, 2011: 32 lacs , 2012 : 19 lacs
B. Sugar yield saving: 2010: 18 lacs 2011: 22 lacs , 2012: 36 lacs
C. Chemicals &consumables saving:2010: 6 lacs 2011: 5 lacs 2012: 4 lacs
Consumer complaints brought down from 0.1BPM to 0.06BPM ( Zero FM in Pet)
Water consumption per case has been brought down from 10.5 liters per case to 9.3 liters /case
Training's conducted to Team Members in PEPSI Quality systems
Lead Auditor for ISO-22000 and ISO 14000.-2004
Success full Qualification of Hot Fill Pet Line in the First Run it Self
Rolled out MOQC, BQT, AIB, IPM, ISO 22000, ISO 14001, water Tool to the concerned staff
3 . PLANT HEAD- MILLY FRUIT PROCESSORS LTD. MOMBASA-KENYA Nov2007-Sept-2009
We are one of the largest mango concentrate manufacturers in Kenya. Apart from this we have business interests in beverages, (vimto, cream soda), packaged Bottled water both bulk &Bottled water) as well as PICANA Brand bottled juices, (Mango, Grape, Orange, Tomato, Apple jUices) Tomato paste. Squashes, RTDs, canned juices, pineapple, mango, orange, grape conc. Production.
Job Profile
Steering overall Plant Operations for manufacture of Fruit Juices, Pulp, Paste, Concentrate, Jams as well as Ketchup, sauces, Soup, Baked Beans, Instant Fruit Pudding etc. under the brand name Papylon, Picana with a team of over 280 personnel
Line Productivity (Overall & line wise.Cost per SKU unit.Water conservation, Maintaining plant within regulatory environmental parameters.Planning with Sales Team for weekly production schedule for all the lines to meet Sales Volumes, decision making in change of schedule to accommodate sales preferences, Downtime analysis, plant capabilities, process capabilities & machinery performance analysis.Planning with Production manager as per product guidelines, product development, SOPs, market complaints, Quality issues, Quality results, GMPs, plant sanitation, hygiene, audits & certification.., Cost control, allocate funds to priority areas, generate feasibility of new projects & their costing, decision making on critical urgent purchases, Co-coordinating with HR function for smooth employee-employer relations, Handling Unions, incentives & rewards, performance appraisals, legal & local food regulatory issues & safety.
Planning with QC Manager for weekly production schedule to meet Sales Volumes, decision making in change of schedule to accommodate sales preferences. Maintenance issues, line efficiencies & downtime reduction. Breakdown & downtime analysis, plant capabilities
Budget preparation for rolling forecast figures from sales, regarding machinery augmentation, line modifications, manpower recruitment or outsourcing, To achieve production targets as per the sales requirement both for the volumes as well as the variants.
Ensuring minimal variances on the RM/PM materials from the budgeted costs. In fact we have been beating the inflation by better variances along with cost effective substitutes support from the supply chain. Implementation of TPM, 5S and Lean manufacturing in the plant. In this we have had huge success in monitoring and control of manpower productivity, machine downtime and operational downtime
Achievements
1. Mango conc. production yield achieved is 58 % against 54%( saving 700, 000 USD )
2. In absence of GM acted as GM and monitored sales and distribution activities
3. In charge of factory Administration and liasoning with all statutory bodies of Kenya.
4. Introduced Minimum Inventory Concept and reduced wastage .
5. Introduced KPI Monitoring system for Line productivity, Total Plant waste, Conc. yield, Etc.
6. Sales Volume increase from 65, 000 c/s per Month to 83, 000 /Month .
7. Zero loss of sales due to non availability of cases to load has been achieved for the season
8. Refurbishment of Fillers /Bottle washers and also commissioning of new fillers for water and squash lines has been done in record 4 months.
Mango conc. exported to UK and other African countries for the first time.
New Tetra blending equipment was dismantled and shifted from India and installed at Mombasa to increase the capacities.
Job Role
Overall in charge of this Packaged Drinking water plant, looking after Quality, production, logistics, materials planning, costing, and general administration
Major achievements:
set up the quality parameters and solved bromate issue
increased productivity from 75, 000c/s to 1, 65, 000 c/sper month
commissioned new shrink labeller and new shrink wrapper
Responsible for Quality Assurance of 6 line plant Pepsi
Ensured FSMS certification and iimproved Quality scores.Implimented 3D Quality .Apart from Monitoring Syp.making, Water treatment, ETP etc,
..
Job profile
Responsible for Quality of the second largest beverages, juices (hot fill Pet &Grb), Mineral water (ANHAR)Manufacturer in Sudan. Annual production 18 million cases.
Achievements
Created sustainable Quality Manuals like Beverage Document, Analytical Methods, SOPs, GMP, Water Tool, Packaging & Raw Material Specification Manuals, Co2 Tool
Standardised all Product Formulations by creating Sensory Panels, trained local team members in Lab Operations and Microbiology, reduced foreign matter complaints from 28 BPM to 1 BPM
Credited with creating a Quality System comparable with any MNC system visible in the Market place
Developed all Documents for Certification of ISO 9000.Standardised Juice recipes as per local market needs, hot filling processes etc.Implemented all Warehousing practices (FIFO, TRADEAGE)
Monitored KPMs through excellent Formats, Documents and Trend Charts, conducted Training Programs on Products for Sales teams.New Product Developments.1. Mango Orange (pet Hot Fill
2. Sugar less mango Juice:) 3. Guava Fruit based Juice(Pet
Standardised the formulation, test Production, sensory Evaluation, test marketing, market Survey and Launching the Product
Job role
Directing all Quality activities for 5 lines, RGB, PET, Juice, Water (total of 1900 BPM).
Handling team of 22 Chemists, Microbiologists, sr. Executives, Operators as well as 120 Workmen
Facilitating the implementation of the Pepsi Quality Plan in letter and spirit; ISO 9000 implementation and audits. Ensuring achievement of KPMs like concentrate / sugar yield, ingredient yield loss, foreign matter, delta sugar, microbiological quality of water, beverage, bore well sanitations, SGA formation and monitoring etc. Handling Aquafina Bottled Water Operations. Overseeing, labor management and quality control. Handling Systems like RO, Ozonation, DM Plant, Coagulation / Syrup / Juice Pasteurization Systems, Sterilizers, Canning Equipment, PET Blow Molding systems and all Laboratory Equipment
Achievements
Achieved 5 I Q A (International Quality Audit) Awards in 6 years; inclusive of 2000 (Gold), 2001, 2002 & 2004 (Bronze) and 2003 (Silver).Won the IQA Facilities Gold Award six times across the tenure with the organization. F.M complaints were brought down from 0.4 BPM to 0.1 BPM
Water consumption was brought Down from 12 Lyres/Case to 9.8 Ltrs / Case. Successfully implemented ISO 9001CertificationProcess.Commissioning of AQUAFINA PACKAGED DRINKING WATER PLANT.The Plant was rated 3 rd for three consecutive years in Quality among 38 plants across India
In-charge Of this White Button Mushroom manufacturing plant
Fermentative production of Phenyl Acetyl Carbinol
manufacturing and quality control of Bio Vaccines like diphtheria, Tetanus, ATS etc.
• (M.B.A) From ICFAI -2005 • IT SKILLS
• M.Sc. with Specialization in Microbiology from M.S UNIVERSITY -BARODA in 1980
• Well versed in MS-Office. • Present Address: S-3, 104, Moraj River side Apartments, Takka (Village), PANVEL- Navi-Mumbai • Permanent Address: F-9 RVR Enclave -Besides Devangakalyana Mandapam .1st Road Anantapur-A.P- • • Languages Known: English, Hindi, Telugu, Marathi, Tamil, Bengali • PassPort No:: F 27 44867. • VALID UP TO: 10-03-2015. • ISSUED AT: HYDERABAD
