vishnu vardhan reddy valisekkagari

• As from my experience I have initiated and established new dry mix detergent cake, powder and detergent liquid factory, which capacity of 1.5 Ton per hour with in expected budget
• Design and develop attractive brand name and develop packaging cylinders as per market requirements
• Initiated compliances certifications from PCB board for CFE, CFO, Factory License, Labour license, Ground water License, NUDA plan approvals, plant layout approvals, Fire dept. approvals, NOC from Gram panchayat
• Successfully installed and commissioned Detergent soap, Powder and Liquid line, Flow wrap Packing machines, Cup filling FFS machine, Liquid filling packing machine
• Researching of Raw materials vendors and getting comparative quotes to fit in budgeted product price
• Established laboratory to set product standard before release in the market and comparative analysis of won brand with competitors product performance
• Established SOP for production, Process and Packing machines maintenance, and quality parameters
• Design the checklists, production checklists, quality checklists and maintenance checklists plant layout
• Training schedules for all workforce operators, maintenance team and general workers

• Ensure that manufacturing process run reliably and efficiently.
• Plan and execute production as per demand and maintain minimum maximum levels.
• Resolving quality related issues such as (Soft soap, Soap cracks, Dull color powder, high moisture powder, low AV value, High Acid value in laundry soap, Toilet soap, Detergent & Sulphonation plants respectively
• Monitor individual machines history and condition, if any abnormalities noticed immediate action to be taken to avoid breakdowns
• Special attention for highly critical equipment’s in Soap Reactor, Vacuum pumps and centrifugal pumps, Wrapping machines, in Sulphonation Heat exchangers, Sulphur pumps, LABSA transfer pumps, LABSA reactor, Brink filters, blowers and High-pressure pump in Detergent plant and hot air generator as well
• Identify where human resources required.
• Determine the material quality selection to achieve high quality products
• Raw materials selection as per required quality standards and regulations and coordinate with suppliers
• Work out and implement standard operating procedures for production operations.
• Ensure implementation and adherence to health and safety procedures.
• Monitor quality specifications and maintain parameters as per set regulations standards
• Set KPI objectives to production and maintenance team to improve the process and run the business with profits
• Review the team performance yearly basis and make planning for trainings where is required to improve the skills and improve the plant performance
• Monitor utilities consumptions per MT of product and set target to reduce conversion cost.
• Monitor waste generations and implement the working procedures to minimize waste levels
• Lead and implementation of ISO, Safety, 5 S auditing and other external/Internal auditing
• Monitoring of utilities log sheets, air compressors, chillers, blowers, and D.G sets for schedule maintenance
• Preparing budget of projects, project Planning to achieve the complete in time
• Costing of local and import materials, negotiation and finalizing.
• Vendor development for machinery spares and fabrications work
• Preparing project completion report and execution of work accordingly.
• Recruiting of local workers as required -mechanical fitter, electrician, and operators.
• Dealing with government people for water and electrical connection and fire dept.
Key Achievement’s in Bidco Africa Limited:
• Re-processed of 2000 Mt of rejected Detergent powder which was produced earlier
• LABSA Active matter quality improved from 95% to 96.3%
• Streamline of Formulation’s
• Energy saving project
Reason for Leaving: I was needed 6 months brake due to urgent family issues

• Plan and allocate manpower for soap plant machinery installation and commission
• Lead daily meeting with team and minutes all raised issues and follow up status of work.
• Set up strong production, maintenance and supporting team
• Coordinate with Mazzoni/Desmet team for installation and commissioning of soap plant
• Procuring and monitor of local and import spare parts and R.M materials and maintain critical spares in stock
• Planning of preventive and corrective maintenance of plant machineries and equipment.
• Monitor individual machines history and condition, if any abnormalities noticed immediate action to be taken to avoid breakdowns
• Special attention for highly critical equipment’s in blowers, Reactor Pump, Chillers, make sure critical spares available in the store
• Resolving quality related issues such as (soap breaking, softness, hardness, over/under weight, color rough texture spotting etc.).
• Raw materials selection as per required quality standards and regulations and coordinate with suppliers
• Monitor waste generations and implement the working procedures to minimize waste levels
• Monitor equipment calibrations and AMC for all utilities
Key Achievements in Wilmar Africa Limited Ghana:
• Successfully completed Mazzoni Saponification and drying soap plant of installation and commissioning included brand design up to Finished product
• Successfully Set up strong production and technical team to run plant efficiently
• Successfully Set up product quality as per regulatory standards requirements
• Successfully Set up raw materials quality standards to achieve finished product as per regulatory standards
• Successfully Set up packaging design artworks and dimensions as per regulatory standards
• Successfully set up laboratory equipment’s selection for analysis of process
• SAP Implementation for PP Module and Maintenance

• Maintenance: Planning & implementing the preventive & predictive maintenance of Plant, machines, personnel, production, equipment’s for improving the overall reliability, safety & maximum efficiency under safe operating conditions.
• QMS Implementation & Compliance- Conducting regular Internal Audits, Root Cause Analysis, Troubleshooting and Reviews to ensure adherence to highest standards.
• Lead team of line managers for better performance of Plant Operations and Regulatory Compliance
• To maintain all machines maintenance equipment and train the local workmen to maintain the machines.
• To plan production schedule as per stocks on hand, Sales demands and minimum maximum levels in the loading bay as set.
• Heading manufacturing operations for Detergents powder plant.
• Leading a 300+ strong team which includes Production, Engineering and utilities, Quality, R&D, Projects, Planning, Stores
• Advising on capacity improvement, business structures, drafting various manufacturing policies and structuring operations.
• To establish and implement employees training on work safety, ISO and 5 ‘S’
• To procure the raw materials as per production planned.
• To establish and implement the Waste Management, and reduce wastage levels.
• To implement ISO and QMS in the plant and establish corrective actions
• To establish and implementing the 5s and Kaizens systems.
• To evaluate team performances and plan and implement any training required to improve on personnel skills
• To plan projects which are coming new equipment’s installation and commissioning to improve the plant efficiencies and project maintenance of all process and packaging machines.
• To plan the preventive maintenance in order to reduce breakdown of equipment and increase plant efficiency.
• To maintain the inventory of spares, tools and other engineering equipment.
• To minimize the machine down time, wastage and increase the productivity.
• To project and control the maintenance annual budgets
• To analyze plant breakdown maintenance and improve periodic maintenance in order to reduce downtime and improve productivity
• To plan and Implement manager’s model in the plant to improve productivity
• To plan and implement reduction of conversion cost where is required
• Lead Validation Team, Service departments, Stores, QC, QA, Projects, Process Engineering, PD Lab, for suggestions, modification and Implementing in the process.
• Developing Production Plans and Volumes, concepts for production optimization, yield improvement to ensure achievement of targets as per budgeted parameters.
• Process Enhancement -To carry out improvement in existing products based on market trends & requirements by cost saving techniques/ measures and modifications to achieve substantial reduction in expenditures and work within the budget.
• Effectively manage all the regulatory audits
• Managing Plant for achieving the periodic production targets. Improving productivity and reducing change-over times.
• Operations of the new set ups for meeting the assigned targets.
• Documentation: Ensuring Manufacturing documents and records regarding process carried out according to desired standards.
• Responsible for opex and capex of the plant.

Main responsibilities:
• Responsible for all engineering preventive and break down maintenance in the plant
• Plan for predictive & preventive maintenance for all machines
• Follow up for Engineering quotations for related modifications in plant machinery
• Making Kaizens in the machines for best quality productivity
• Implemented for manager’s model to improve plant efficiency
• Prepare weekly engineering status reports and reporting to Management
• Plan and supervise of new machineries installations & commissioning for sister concerned units and management allotted jobs
• Plan and schedule preventive maintenance of Utilities
• Implemented 5’S’, ISO, HACCP to Improve Productivity and QMS
• Plan and establish action plan to minimizing breakdowns and adhere to availability of machineries for users.
• Project and plan engineering team job allocations
• Analyze plant breakdown and improve periodic maintenance in order to reduce downtime to improve productivity

• Plan and attend all preventive maintenance and breakdown maintenance activities
• Carrying out necessary modifications as user requirement on plant machinery
• Implemented for manager’s model to improve productivity
• Project and plan engineering team job allocations
• Prepare and report weekly engineering report to maintenance manager
• Plan and supervise of new machine installations and commissioning of machineries in new blocks
• Plan and supervise of maintenance for Utilities
• Supervise and implement 5’S’ activities, HACCP, Improved Productivity, and QMS
• Plan and establish action plans to minimizing breakdowns and adhere to availability of machineries for users
• Plan and implement of technical training schedules for technical team

Project held in Pale Products Pvt Ltd:
1. Fabricated mini stacker in the plant to minimize the re-cycling of biscuits and participated and presented in best natural resource saving performance competition in QCFI- Kolkata in 2008, achieved best project second runner from Quality forum of India

• Handling of all process lines and packing machines operation and carryout preventive and productive maintenance in order to reduce breakdown
• Plan and prepare of machines daily check list in order to improve productivity
• Plan and implement operation and maintenance of following major machines: G.P. machine, Mico Bosch machines Terra 25 (Bosch group), Select Packing machine (Samarpan group), Flex Machine, Target Engineering machine, I.T.W. Carton Sealing machine, Robo Packing machine, G.P. machine, Select Packing machine (Samarpan group), Flex Machine, Target Engineering machine, I.T.W. Carton Sealing machine, Robo Packing machine, Multivac machine, Ilpra machine, Band Sealer machine, Ishida Weighing Scale, Yamato Weighing Scale, Liquid multi head packing machines, Multipack Wrapping machines, Potato crisps line capacity: 500 kg per hour, Automatic fryers.
• Plan and allocate operation and technical team

• Assembly & testing of liquid (water, milk, oil, etc.) packing machine.
• Preparation of daily check list of machines which are ready to ship
• Plan and complete of machine assembling with in target time
• Plan and supervise of technical team
• Plan and allocate technical team to get technical assistance in time
• Daily updates on service & production reports to the management