Rahul Banerji

**** *. ******** ******, ********, CA 92374. H: 951-***-**** C: 951-***-**** ac1ojz@r.postjobfree.com

DEDICATION LEADERSHIP RESULTS

Highly motivated and results-driven self-starter with over 18 years of US & international experience in plant management for small and mid-sized American and subsidiary European companies within the plastics industry. Strong interpersonal skills, proficient in fostering positive professional relationships and communicating effectively at all levels. Strong plastics processing background. Materials: PS, PMMA (acrylic), HIPS, ABS, PC, PET, Nylon and GF-Nylon, PPO, PVC, HDPE, PP,TPO, TPU, COPP in molding and HDPE, HMWPE, LDPE, LLDPE, VLDPE, PP, PVC, PVDF, PS, ABS, PC, EPDM, in extrusion, thermoset PU foam for carpet underlay. Hands on experience in injection & blow molding, large part compression molding (FRP-glass fiber, mineral – talc, mica filled, foamed) of composites, gas assist molding, extrusion - sheet calendaring for manufacturing liners for waste management landfills, roofing, extrusion for pipe, tubing, hoses, netting, profile, film, polymer compounding, blow-molding, vacuum forming, inline or secondary laminating and plastic testing. US Citizen with extensive international travel experience-willing to relocate immediately now and for future opportunities.

AREAS OF EXPERTISE

Deep knowledge of plastics materials and processes and general manufacturing industry. Developing best practices for process & product enhancement. Manage Plastics Resin Suppliers technical and pricing relationships.

RCA for Processing & Operational issues

Kaizen/Lean Manufacturing/ KPIs, MSR monitoring

Estimating & Costing

Sourcing Procurement Purchasing

Total Facilities Management

Leadership & Team Development

CS, Sales & Marketing Support

SOX & Regulatory Compliance

Change & Diversity Management

ISO-TS, HACCP, GMPs

Delegation & Accountability Mgt.

Negotiation & Bid Solicitation

Hiring & Capacity Planning

Continuous Improvement

Cost Reduction & P&L

Organizational Development

Analytical Problem solving skills

Excellent presentation skills

Proposals & Report Writing, Overseas Reporting

PROFESSIONAL EXPERIENCE

Plastics Manufacturing & Industrial Operations Consultant, May 2015 - Present

§Leverage extensive industry experience in consulting on international sourcing and supply chain, techno-commercial feasibility, plastics processing issues, sizing and recommending purchase of new and used capital, plastics processing equipment, and ancillary and auxiliary equipment.

§Provide trusted guidance and direction on setup and rigging in existing manufacturing facilities, training on industrial safety and safety compliance and setup of standard manufacturing metrics.

§Completed consulting for a custom Specialty Plastics Engineering Compound manufacturer in southern California.

§Recently consulted for investment group for acquisition of Custom Injection Molding Business in Southern CA.

Branch Manager, Leggett & Platt, Carpet Cushion Division, Ontario Operations, CA July ‘14 – May ’15 – Workplace dispute. Unwilling to overlook undocumented/illegal entrenched legacy employees as well as temp workers

Overall responsibility of branch operations including P/L & SOX compliance over two focus factories manufacturing prime and re-bonded extruded thermoset polyurethane carpet underlay. Key Achievements: Stopped all provision of carpet underlay theft by making and facilitating key process and program changes. Improved production run rates and efficiency by 12%.

SHARP PROFILES A J.R. SHARP CO., Adelanto, CA

VP/GM Operations, February 2012-February 2013 - Corporate downsizing & cutbacks

§Spearheaded overall manufacturing operations including P&L of custom extruded and designer pad printed plastic edge-banding for the furniture, kitchen and fenestration markets. Focused on bottom line profitability, stream lining operations including: supply chain, procurement, safety, material handling automation, regrind utilization, die modification projects, metrics and training of personnel.

§Used comprehensive industry network to source international plastics machinery and tooling.

IEC, Pittsburgh, PA (Sales – 9M)

Operations Manager - Plastics, June 2009-Dec 2011- Growth and advancement.

§Responsible for all plastics manufacturing business operations of manufacturing entity including provision of trusted guidance on tooling and processes for medical device housings and enclosures. Oversee design and development of housings for Medical Devices. Selecting plastic materials for the housings. Job Estimating & costing. Working with mechanical engineer for the mold design. Identifying mold manufacturing and plastic injection molding companies. Monitor third party mold manufacturing processes. Setting up the prototype and pilot productions with suppliers. Initial monitoring and Completion of requirements for mass production for the housings. Ensured JIT delivery to end users.

NESTLE WATERS NA, Arrowhead – Cabazon, CA (Sales - 80M - 320 emp)

Container Manufacturing Manager, May 2007-August 2008 - Corporate downsizing for market re-consolidation

§Oversaw all plastics end operations of bottled spring water; Time and performance management of maintenance technicians of Tool and Die Mold Shop involving CNC Milling Machines and Wire EDM machines; Time and performance management of Injection Molding (Husky) and Blow Molding (Sidel) Teams. Supported ISO, HACCP and GMPs efforts.

§Liaised with PET resin manufacturers for material trials and validations and with Husky and Sidel for new equipment validation.

§Provided corporate support of new line layouts and plant expansion on west coast.

Key Achievements:

§Successfully completed NPIs and NIQPs and launch of feather bottle project for weight reduction of half liter PET bottles. Saved $1.1M in power costs from pneumatic losses by bottle mold designs and pneumatic circuit reconfiguration in a team effort.

BRUCE PLASTICS, INC. – Pittsburgh, PA (Sales - 11M - 76 emp)

Plant Manager (Interim), June 2006-March 2007 - Downsizing and plant relocation. Currently closed.

§Skillfully handled day-to-day operations of the manufacturing facility for a unionized custom injection and blow molding operation with small and mid-sized products for the household, confectionery, medical, automotive, pharmaceutical and defense markets.

§Oversaw all facets of the manufacturing facility including but not limited to production, job estimating & costing, Tool & Die-Mold Repair Shop, facilities maintenance, Quality Control and Shipping and Warehousing.

§Coordinated plant closure and gradual consolidation and relocation of business assets to new manufacturing facility down south.

Key Achievements:

§Negotiated continued smooth operations with union after disclosure of company intentions to close plant and relocate business down south to Anderson, SC.

§Honored and ensured completion and timely delivery of all orders to customers from Pittsburgh-PA Plant and facilitated a smooth transition of customer orders to newly relocated plant in Anderson, SC.

COMPOSITES TECHNOLOGIES CORPORATION, A Soin International Company, Dayton, OH (Sales - 17.5M - 95 emp)

Plant Manager, March 2005-June 2006. Growth & Advancement

§Managed plant with products made with filler (FRP – Glass fibers, talc, mica) reinforced plastic by extrusion compression molding like pallets for the automotive, material handling industry, basketball boards, snow-boards, transformer pads, low cost modular housing, wagons, and utility boxes. Spearheaded ERP implementation and upgrade of all IT hardware, software and peripherals. Supported regulatory compliance for ISO-TS 16949

§Handled overall manufacturing and assembly operations including production, Tooling, Maintenance, Shipping and Warehousing, facilities expansion, plant re-engineering and spearheading Lean implementation.

Key Achievements:

§Increased productivity and run rates by 25-50% on most products for a turnaround.

§Completed 6 molding cell enhancements and 1 new cell project implementation under project deliverables.

§Reduced Labor variance and manufacturing overheads variance by almost $10K/month.

§Reduced scrap by 2% or almost 6K-10K/mo. Stopped customer returns.

§Saved $45K in procurement on off and wide specification virgin plastics resin feedstock as well as reprocessed and regrind plastics feedstock.

§Reduced external warehousing costs by $2500/mo by disposition of all redundant raw material and defunct and retired finished products.

KAF-FLEX, A HEYCO PRODUCTS CO., Tampa, FL (Sales - 12M - 36 emp)

Director of Operations, September 2002-December 2004. Downsizing and plant relocation. Currently closed.

§Directed operations with products including PVC clear tubing and co-extruded tubing, conduit and hoses for the Pool & Spa, HVAC, marine and electrical markets. Coordinated injection molded fitting supply chain for PVC flexible conduits and spa hoses.

§Ensured optimal overall performance of the manufacturing unit in Tampa, FL including Estimating & Costing & shared P/L.

§Project in-charge of plant closures (Burbank, CA), partial relocation and new plant erection (Tampa/Phoenix)

§Oversaw hiring, team building, ushering in lean manufacturing concepts and delegation of duties to Production dept and Tool and Die Repair Technician.

§Functioned as Safety Director and coordinator of safety programs for OSHA compliance. Facilities Management

§Broad based responsibilities included recommending and specifying all ancillary and auxiliary equipment. Also responsible for specifying and purchasing plastics resins and compounds.

§Coordinated, managed and executed all engineering projects for phased expansion, facilities enhancement maintenance as well as introduction of new product offerings in the industry.

Key Achievements:

§Acquired ISO 9002 certification and successful manufacturing, certification and introduction of 10 flexible hose, tubing conduits for the spa, marine and electrical markets.

§Reduced scrap by 11% during tenure.

§Successfully negotiated disposition of co-extruded rigid/flexible PVC scrap thereby generating additional revenue.

§Reduced labor turnover by 20%.

§Spearheaded ERP and IT implementation projects.

§Initiated and completed project deliverables for 6 additional cells/extrusion lines.

PRIOR EXPERIENCE

§Engineering Process Manager, OWENS BROCKWAY, Baltimore, MD, Division of Owens Illinois, Toledo, OH (Sales – 58M - 345 emp), January 2001-November 2001. Corporate downsizing and cutbacks for market reconsolidation & future sale

Director of Manufacturing, Promoted from Plant Manager, TENAX CORPORATION, Baltimore, MD, division of Tenax Spa, Italy. (Sales – 20.5M – 85 emp), February 1996-December 2000. Growth & Advancement

§Promoted from Plant Manager. Products: Extruded engineered plastics netting web for waste management, drainage, road grids, agriculture, construction, safety, horticulture etc.

§Overall responsibility of manufacturing operations including P/L in Baltimore, MD. Managed 5 salaried direct reports. The departments of production (plastics netting extrusion including foamed netting, geonet/non woven geotextile lamination and packaging), maintenance including Tool and Die Shop, facilities maintenance, plant safety, quality control, operations (scheduling and logistics), warehouse and shipping as well as implementing lean manufacturing fell under my purview.

§Liaised with European parent company in Italy. Responsible for translating sales budget into production, direct material and direct labor budgets. Responsible for estimating and costing of netting and geocomposites.

§Additional responsibilities included managing projects for phased expansion, determining manpower requirement and hiring, specification and procurement of plastics resin, capital machinery, and auxiliary and ancillary equipment. Involved with new equipment startups, documentation and new product qualification process.

Key Achievements:

Successfully completed a material selection and process and tooling modification project at Tenax Corp. Baltimore, MD, to improve the product performance of the existing tri-planar tendrain netting and the capping net, which are industry leaders in their class in the waste management industry. Improved operational efficiency and facilitated equipment modification resulting in savings and adding substantial potential business.

Completed a $3.2M phased expansion project of manufacturing facilities in 30 weeks.

Saved the company over $60,000/yr in resin procurement.

Reduced manufacturing budget variances by 10% over previous years.

Technical Director, Promoted from Plant Manager, AGRU AMERICA INC., Canton, MA, div. of AGRU Alois Gruber Gmbh, Bad-Hall, Austria (Sales-9M - 20emp) August 1992-November 1995. Company sold & relocated.

Products: PP(industrial piping) PE(gas) and PVDF Pipes produced with clean room extrusion (high purity water, pharmaceutical manufacturing dealing with medical chemicals, UV sensitive chemicals, gas, de-ionized water) and PE sheets (geomembranes, industrial sheet liners for landfills, reservoirs, roofing, gold mining, concrete lining made by sheet extrusion). Overall responsibility of the manufacturing facility. Responsible for hiring, delegation of duties, oversee set-up of extrusion lines, calendering and ancillary equipment, Tool and Die Shop, troubleshooting our pipe and sheet extrusion lines and preventive maintenance of extruders, downstream equipment, chillers & boilers (systems) and overall facilities maintenance. Responsible for training subordinates in ASTM procedures and the usage of testing equipment for quality control. Liaised with European parent company. Reported to President, Agru America.

Key Achievements - Improved run rates by 15%, purchasing price variance (PPV) gains by 10% and reduced manufacturing Overheads by 12%. Improved operational efficiency by 15%. Reduced geomembrane scrap to less than 1%. Successfully developed five more product lines in the sheet liner/geomembrane business at A/A Manufacturing Inc., Canton, MA, by way of reducing the gauge thickness of our extrusion calendered smooth liner from the previous minimum of 60 mil to 40 mil and 30 mil respectively, and the structured geomembranes (grip, drainage net & super-grip) from the previous minimum of 80 mil to 60 mil, thereby adding $1.5 million in potential business per year. Saved company 50K a year in resin procurement.

EDUCATION

§Master of Science in Plastics Engineering (GPA - 3.6/4.0), UMass Lowell, MA, 1992

§Financial Accounting I&II, Business Sales & Marketing I Courses in community college– 2009, 2012 (GPA 4.0)

§Post Graduate Diploma in Plastics Engineering & Tech (PGD-PE), Central Institute of Plastics Engineering & Technology (C.I.P.E.T), Chennai, India (GPA-3.5/4.0), 1989

§Bachelor of Science in Mechanical Engineering, Maharaja Sayajirao University, Baroda, India (GPA – 3.5/4.0), 1987

§Diploma in German, M.S. University, Baroda, India (GPA – 3.3/4.0), 1986

§Softwares: Windows & AS 400 based ERP/MRP, Data Acquisition software, Windows, MS-Office Suite.

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