Operations Manager proficient in Lean manufacturing, Six Sigma & TPM

Dipesh Vaidya

*** ********** ***** *****, *********** ON L5R 1P3 Tel: 647-***-**** Email : ******.******@*****.***

PRODUCTION AND OPERATIONS MANAGEMENT

Business-savvy and highly-knowledgeable operations leader with years of expertise in the design, management and optimization of manufacturing operations. Brings astute understanding of what it takes to realise and sustain best-in-class production operations in national organizations. Offers success in multiple aspects of business operations from financial management and cost control to production planning, product engineering, staffing and material sourcing. Highly adept in analysing existing processes to devise and implement improvements through Lean manufacturing, Six Sigma and Total Productive Maintenance.

CORE KNOWLEDGE AREAS

• Consolidated Operations & Production Management

TPM, Lean Manufacturing & Six Sigma • Theory of Constraints • Inventory & Replenishment Management

• Contract Management • Budgeting & Cost Control

Team Leadership & Motivation • Change Management • Efficiency Improvement Strategies

PROFESSIONAL EXPERIENCE

OPERATIONS MANAGER NOV 2008- SEPT 2009

BARZEL INDUSTRIES INC (formerly known as Novamerican Steel Inc.), Granby, Quebec

Hired by this steel processing company to coordinate production at three plants in Granby and St. Hubert.

Achievements

• Led a unionized team of 40 production workers and 3 supervisors towards meeting production goals.

• Identified the operational, workflow, and motivational inefficiencies of the department through extensive work measurement and time studies.

• Achieved noticeable and sizable reduction of quality defects through streamlining processes, implementing corrective actions, and improved production accuracy.

• Improved the productivity of roll forming machines by reducing the set-up times by 20% using lean manufacturing tools.

• Developed and implemented “Deployment flow charts” for plant operations as part of the change management to streamline the manufacturing process.

• Utilized the deployment chart to map the business process for implementing a new ERP system.

• Consistently met and exceeded production targets through root cause analysis, process control, statistical evaluation, work measurements, time studies and a host of other methodologies aimed at aligning superior process standards with required production targets.

• Standardized components to reduce manufacturing and outsourcing costs.

• Monitored and analyzed financial and operational metrics using SPC techniques on a weekly, quarterly and annual basis to ensure compliance with distribution plans and service requirements.

• Planned and prioritized staff resources to ensure that stringent timelines were met.

• Monitored project progress and milestones to address any bottlenecks, quality control concerns or other production issues.

• Led the engineering team, enforcing production best practices that save time and cost without compromising product quality, increasing sales by 10%.

• Implemented a preventative maintenance system for roll forming mills and reduced the downtime of the mills by 15%. Also implemented 5S on the shop floor to reduce waste.

• Coordinated with supply chain, marketing and engineering departments to ensure that business objectives were met.

MANUFACTURING ENGINEER SEPT 2007- SEPT 2008

3M CANADA COMPANY, Brockville, Ontario

Originally brought on board by this diversified technology company to carry out a continuous improvement project for waste reduction and was retained for an extended one-year contract.

Achievements

• Planned and rolled-out a Continuous Improvement (CI) project for waste reduction leading to 7% improvement in waste for the organization. Recommended alternate cost effective means of disposing waste by using waste tapes as paper pellet fuel.

• Developed a training package on the new quality testing method and facilitated training sessions for staff to equip them with the tools to be productive & cost-effective manufacturers.

• Conducted trials on a newly installed production equipment to determine specifications for critical control points and establish bench mark for process capability.

• Led a Six Sigma green belt project, utilizing the principles and management techniques necessary to resolve issues and problems through the implementation of appropriate corrective tools and methodologies, leading to annual savings of CAD $50,000.

.

ENGINEERING OFFICER JUL 2004 – AUG 2006

PRODUCTION OFFICER JUL 2002 – AUG 2004

HINDUSTAN UNILEVER LIMITED (UNILEVER GROUP COMPANY) India

Initially brought onboard by this global consumer goods production company to coordinate production phase and was later promoted as an Engineering Officer to provide key engineering, operational, and workflow solution support. The Plant was TPM level II certified by the Japan Institute of Plant Maintenance.

Achievements

• Led the Jishu Hozen ( Autonomous Maintenance) pillar and Circles undertaking waste reduction and efficiency improvement projects

• Responsible for all the engineering issues for a plant generating CAD 20 million in revenues annually. Managed a budget of CAD 300,000 for maintenance activities and CAD 150,000 for capital projects.

• Received an award for Excellent Performance in TPM in 2004 by leading a technical team to improve productivity of sachet packing machines, improving machine efficiency (OEE) from 70% to 85%.

• Reduced packing material waste for laminates and spouts from 10% to 2% by implementing kaizens.

• Implemented GMPs and HACCP for the production of creams, lotions and shampoos.

• Contributed significantly to improve safety indicators; Reduced reportable incidents by 50% and attained the goal of zero accidents.

• Improved overall operations through employee retraining, team building, morale boosting, and motivation.

• Sourced and negotiated profitable contracts with third-party vendors & supplies, securing cost savings without compromising quality standards.

• Worked with cross-functional teams to increase employee safety awareness, effectiveness and activity through the creation of technical instructions, the training of operators, and general adherence to plant standards.

EDUCATION

MASTER OF MANUFACTURING MANAGEMENT, May 2008, McGill University, Canada

BACHELOR OF MECHANICAL ENGINEERING, May 2001, University of Amravati, India

DIPLOMA IN MECHANICAL ENGINEERING, Jun 1998

Shri B.M Polytechnic (Autonomous), India

COMPUTER SKILLS

• ERP Software Packages like Mfg-Pro (Planning module), Styeline,

SAP (Materials Management Module) • MS-Office applications

Contact this candidate