Production Manager
IFFCO (International Food Stuffs Company)
Total years of experience :24 years, 0 Months
Managed production of Tiffany/Noor/Hayat/Alfa brands Tomato Ketchups, Specialty sauces, Tetra pack fresh milk/flavored milk/juices/cooking cream/whipping cream/Ice cream mixes, Mayonnaise & industrial trials for 25 lines of total 163 personnel (06 officers - Direct Reports; 157 workmen - Indirect Reporting)
• Ensured productivity of resources in respect of machines, manpower & materials including capacity utilization
• Ensured adherence to safety procedures, process quality parameters & end product quality norms
• Framed optimum manning strategies, multi-skilling and high degree of workmen motivation as was evident in their problem solving approach, willingness to stretch and willingness to collaborate with other teams
• Framed annual manpower forecast budget, material losses budget & Capex budget proposals
• Ensured Factory Overhead Cost (production related) is within approved budget
• Successfully conducted industrial trials for new products to establish quality parameters, component scraps & related studies thereof
• Periodically reviewed performance of Production Executives, with objective of improving performance, building result orientation approach, development as future leaders and succession planning by activating a work force career plan in collaboration with Unit HR team
Key Accomplishments:
Achieved debottlenecking of manufacturing operations by suggesting alternate processing method of hot sauce & water based specialty sauces thus increased production capacity @120mt per month
Reduced CIP time by 1 hour in one of the processing lines thereby increasing production capacity @ 30 tons per month
Reduced edible oil losses from 3% to 1.4% by pointing out a change in software which enabled use of a flow switch as a flow meter resulting in fine dosing of oil during processing
Managed production of Maggi brand Noodles/Soups/Bullions/Tomato Ketchup products & ind. trials for 13 lines of total 262 personnel (20 officers - Direct Reports; 242 workmen - Indirect Reporting)
• Key member of OE (Operation Excellence) team for selecting/supporting/coaching improvement teams using DMAIC methodology (Six Sigma)
• Served as FI (Focused improvement) team member in TPM structure
• Provided technical support relating to food safety/good manufacturing practices/ effective utilization of available space & assets/workmen safety to project team during commissioning activities in my area
• Successfully conducted industrial trials for new products to establish quality parameters, component scraps & related studies thereof
• Forecasted annual budget relating to production consumables, manpower (basis sales forecast) & demonstrated a projected savings from budget amount for consumables
• Oversaw production planning & manpower planning for 13 lines, 90 SKU
• Trained subordinates for SAP & problem solving methodology
Key Accomplishments:
Reduced NQC (Cost of Non Quality) from 1.74% to 1.2%
Maintained MSA at 99.8% level
Saved 1% in Annual Consumables Budget
Fetched PASSION TO WIN award (Idea Recognition scheme within company by CMD) for reducing processing time of drying oven from 21 to 16 hours by suggesting a change of hot water circulating pump type thus saving 0.7 million INR annually
Reduced overtime from 3.2% to 1.6%
Managed shift operation of Cadbury brand chocolate products Five Star/ Wafer Biscuit category (Perk, Milk Treat, Ulta Perk) of 03 lines overseeing 54 personnel. Accountable for QSCSP balanced agenda, Monthly Plan Achievement (MSA, PAI, SAI), MIS, MUV, EHS, SAP, OEE (Overall equipment Efficiency), manpower optimization
Key Accomplishments:
Increased yield of raw materials @ 2% by consuming rework generated in milk treat chocolate production through a new rework usage technique
Managed shift operation of Kissan brands Jam & Marmalade/Tomato Ketchup/Squash production of 04 lines overseeing 26 personnel each. Accountable for QSCSP balanced agenda, weekly plan achievement (MSA), manpower optimization, raw & packing material yields. Accountable for packing area too, having 03 lines of 26 personnel each where capping, labeling, coding, shrink wrapping as well as final packing was practiced
Key Accomplishments:
Increased hourly output of tomato ketchup line from 800kg/hour to 1 ton/hour by pointing a change in homogenizer valve design
Reduced defect per million opportunities in packing area by educating team & enhanced monitoring thereof
Managed shift operation in online Quality testing of Coca Cola brands Coke/Limca/Fanta/Sprite/Thumbs Up/Diet Coke/Kinley Bottled Water & Soda Bottling operations in both glass as well as PET formats. Accountable for water treatment plant testing, bottle parameters (PET Bottles), Wet Bottle Coding using DOMINO printers. Active member of Internal Auditors within group. Certified Lead Auditor for ISO 14001:1996, EMS & handled Effluent Treatment Plant
Key Accomplishments:
Improved water quality of effluent treatment plant to meet local legislation by suggesting changes in clarifier RPM
Increased raw material recovery of CO2 from 68% to 79% by pointing out a potential leakage in line
Managed Milk Procurement routes for collecting quality milk from villages by planning 30 routes of milk vehicles, educating 36 testers sent along with vehicles, calibration & distribution of milk testing apparatus (lactometer/Pipette/Butyrometers/Chemicals/machines) to 125 milkmen
Key Accomplishments:
Reduced cost of quality by procuring good quality milk which contains less water as adulterant
Key Accomplishments:
Suggested new design of brush for cleaning of 30ft high holding tube of Evaporator that decreased black particle in final product
Handled shift independently in production department for 1 month & in quality department for 7 days
Merit Scholarship Holder in 10+2