Unit Head
GEPIL
Total years of experience :25 years, 6 Months
Key Result Areas:
Provided Creative Leadership as Plant Head for the overall organization, directed management and controlled all functional departments at unit level
Planned, organized, directed and controlled the operations activities to achieve desired levels of output in terms of productivity, quality and unit costs
Safeguarded shop floor has the necessary manpower, competence, skill, knowledge, plant and tooling required in order to achieve production targets
Engaged in business development, customer service, operation, R&D, lab, commercial, finance, logistics projects and liaising
Synchronized corporate & site to follow all policies and guidelines; set targets and motivated team to achieve the same
Ensured compliance of ISO 9001/EMS 14001/OHSAS within the unit & established systems for all possible processes for smooth functioning
Adhered to all legal & statutory norms and authority (MOEF/CPCB/TNPCB)
Prepared, controlled and monitored budget/MIS/cost of respective functions
Significant Achievements:
Expanded projects by doubling the capacity; added many new clients and simplified their complexity of wastes disposal
Recognized for achieving the production targets by 150%
Minimized production cycle time by 1 day against 3 days previously
Reduced wastage of raw material by 12% by taking steps to reduce recycle
Improved the plant capability by 200% by taking expansion projects
Took initiatives to streamline / enhance production processes (by rewriting Standard Operating Procedures, implementing 5S and including many machineries required for production)
Key Result Areas:
Spearheaded complete plant operation, maintenance, sourcing, budgeting, planning, scheduling, dispatching, maintaining quality, licenses and govt. obligations
Acquired certifications like GMP, AYUSH, ISO 9001:2008, Halal
Managed commercial activities pertaining to New Product Development
Executed many knowledge sharing sessions and maintained spirit of performance
Managed contract unions, designed and implemented 360 degree view of contract related information, tasks, activities and correspondence with legal
Liaised with excise/export duty and sales tax offices
Significant Achievements:
Implemented ‘My Ideas’ KAIZEN with more than 30 ideas
Built Maintenance Team as the only team to support & execute KAIZEN and resolve any problems encountered
Brought continuous power supply by separate Industrial feeder, thereby avoiding diesel consumption
Reduced theft to zero by implementing surveillance CCTV and regular meeting to improve behavior skills measures; proposed Lean Structure in existing infrastructure
Initiated CSR activity by planting more than 500 plants, small gardens, organic mango groove
Simplified export procedures by implementing star status
Key Result Areas:
Leveraged process diagnostics and benchmarking, devised scenario-based strategies and implemented lean principles to improve operational efficiency in supply chain
Optimized manufacturing performance and improved asset management
Used analytical and quantitative methods to understand, predict, and enhance supply chain processes
Significant Achievements:
Improved productivity by 40% and reduced non value added cost throughout the value chain by 20% by improving visibility and velocity of different chain.
Created the following:
o Business Process Material List (BPML) for chemical industry
o Chemical Template with list of business process ready with SAP, Oracle, I2 Technology Solutions, ready to implement and on demand solution
Worked as a Client Partner to develop bidding documents, digitalize and automate few processes, harmonize, integrate and optimize the color development process and resolve business problems using statistical models
Performed KPI scoping and alignment for creating enterprise data warehouse for PPG and reduced overall Total Cost of Ownership (TCO)* and brought 50% reduction in application development and support and 40% reduction in infrastructure cost
Implemented the following:
o Carbon Footprint Assessment for a chemical manufacturer
o Supply Chain Design KPO for a global process-manufacturing
o Product mix configurator on the web for PPG US
Growth Path:
Nov’01 to Nov’04 Assistant Manager - Production / Projects
Nov’04 to Jun’07 Assistant Manager - Materials
Significant Achievements:
As Assistant Manager Materials
Reduced inventory of MRO items by 16% by introducing min/max stock level model
Eliminated one big warehouse for storage of rock by high stacking
Implemented plan to reduce inventory and cost of procurement by localizing and importing materials
Outsourced maintenance of chemical parameter for Boilers, Desalination Plant, Cooling Towers, thereby reducing risk of asset life and sustainable dosage by experts
Managed inventory turnover worth 100Cr
Implemented e-procurement and e-auction along with SAP MM as Power User
Automated PR to PO cycle and reduced purchase manpower from 6 to 4 persons
As Assistant Manager Production / Projects
Reduced water consumption from 97Kl/hour to 72Kl/hour by design modification in ammonia storage plant
Treated and reused cooling tower blow-down water in plant
Significant Achievements:
Improved the yield of Para-Nitro-Chloro Benzene by shifting the equilibrium, by adding Ortho-Nitro Chloro benzene before reaction by 10% - a R&D project to meet the demand of PNCB; was appreciated and rewarded with cash