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Injection Molding Plant Manager

Downers Grove, Illinois, United States
January 17, 2018

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Rajesh R Wadhwa

Woodridge, IL (Greater Chicago) Cell: 1-260-***-****


Results and P & L driver with wide-ranging experience, turning around manufacturing operations with revenue upto $90 Million. Track record devising, evaluating, and implementing continuous process improvements to minimize waste and reduce costs while maximizing quality and yield. Established effective quality control and safety programs, encouraging proactive participation across the manufacturing floor. Excellent communicator; success building cohesive teams focused on production goals, safety, and throughput. Extensive experience in business management delivering consistently on profitability objectives, customer satisfaction, and leading teams to deliver outstanding results.


Business Management, P&L Responsibility, Global Operations & Manufacturing, Lean & 6 Sigma Methodologies, Program Management, Plastics Engineering, Footprint optimization & Strategic Planning,


Essentra, Charlotte, NC, 7/17 – present, Management Consultant (Contract position)

Pharmaceutical printing and packaging solutions plant running 24x5.

Leader of turn around team.

Directing the Quality Engineering team to analyze customer complaints to implement corrective actions.

Resulted in quality improvements by 30% +

Instrumental in improving on time delivery from 50% to 92% in 6 weeks.

Led improvements in Safety, Quality, On Time Delivery & Quality.

Home Products International, NA(Chicago,IL) 3/15 – 7/17 Director, Operations

4 shift union plant running 24x7 with 5 direct & 220 indirect reports.

Improved profit by 3% in 1st year

Proactively improved plant efficiency from 85% to 92%+ in 1st year.

Formulated and implemented annual budgets of $23 MM expense with $90MM sales revenue in 2nd year.

Instrumental in changing safety culture of the plant leading to a record 180+ days without an OSHA recordable from 14 OSHA recordables in 12 months in 2nd year.

Successfully improved product quality in each year.

Successfully sourced over 40+ molds from China in 2 years, investment of $3 million+.

Completed complex state of the art projects like In Mould Labeling & compression injection molding.

Prepared justification and led implementation of all capital projects.

Conversant with AS400 Based ERP system

Ennis Flint Inc, Niles, IL, 5/14 – 3/15, Plant Manager( Plant moved to NC )

Injection molding of high reflectivity lenses in plant running 24 x 5

Reduced lead time by 2 weeks & increased profitability by 5% in 3 months.

Successfully implemented efficiency improvement processes. Improved efficiency by 5%+.

Proactively implemented safety processes.

Processes used Injection Molding, Sonic Welding, Automated Assembly & Coating and Glass Application.

Initiated Capacity Expansion by 30 % at 10%+ savings in Capital.

Group Dekko, Garrett, IN, 8/10 – 5/14: Plant Manager

3 shift non-union plant running 24x5 with 6 direct & 200 indirect reports.

Instrumental in reducing Quality PPM’s from 12000+ to < 200 in 6 months for Whirlpool products.

Turned around plant from loss making to making profit in 6 months.

Optimized manufacturing footprint resulting in significant cost reductions.

All round improvements and customer satisfaction helped plant to grow from $30MM to $70MM in 4 years.

Initiated Lean Continuous Improvement & Cost Savings Program with 3%+ ($1 Million) of Net Sales ($30 Million) Goal. Programs initiated on track in 1st Quarter to save $700 K+ annualized.

Replaced labor-intense processes by enhancing workflow through lean methodologies that reduced staff by 15 on 5 assembly lines in 2nd year.

Successfully mentored 2 Six Sigma candidates. Implemented related Cost Savings Projects.

Processes include Injection Molding, Wire Cutting, Curing, Screen Printing, Painting, Insert Molding, Terminal Stamping, Sonic Welding, Hot Plate Welding, Spin Welding, and Automated Assembly.

Awarded 2012 Operational Excellence Award for Manufacturing Variance Reduction

Increased EBITDA by 50% with only 20% increase in Sales Revenue.

Reduced Scrap by 1.5% ($450K) of Net Sales.

Successfully led the plant to complete renewal certification of ISO 9001 & ISO 13485.

Conversant with AS400 Based ERP system

Developed strong relationships with customers Whirlpool (Appliance), Phillips / Zimmer (Medical Devices), Herman Miller / Steelcase (Office Furniture) & Harley Davidson (Automotive).

AEES–(formerly Alcoa Electrical & Electronic Solutions),Mattawan,MI,8/08--8/10:Plant Manager / Engineering Manager,

Improved profitability by 6% + by eliminating quality concerns using systematic & scientific molding techniques.

Led and Managed Operational Excellence Focus across the location, exceeding the goals set by the Management resulting in direct savings of over $1MM/year..

Managed 9 Direct Reports including 3 Manufacturing Engineers, 2 Program Managers, 1 Quality Engineer, 1 Costing Engineer, 1 Change Notification & 1 Administrative Assistant.

Develop & lead operational excellence teams to improve Quality & save operating costs leading to savings of over $500K in 6 months.

Implemented state of the Art Technologies like Mold Vision, UV Potting, Process Control using Mold Sensors for the first time at AEES/EPC.

Processes included Precision Injection Molding (111 Machines), Automated Assembly (70 Machines), Sonic Welding, Vibration Welding. 128 cavity molds with Hot Runner system and poke-yokes with vision systems. Metal Stamping, Terminal Stamping processes.

Led the Planning and every phase of Implementation of Move from Michigan to Mexico of 80+ Injection Molding Machines & 10+ Stamping Machines.

Recruited complete team of Mangers, Engineers & Superintendents to manage the new plant in Mexico.

Excellent relationship with automotive customers like Ford, GM, Chrysler, Lear, Continental.

Waterloo Industries/MasterLock (Fortune Brands), Oak Creek, WI,7/07–8/08, Manager, Plastics Engineering

Design for manufacturing for plastics and outsourcing materials for production, specifically in the areas of casting, plastics & sheet metal.

Direct, Plan & Review FEA Analysis – static and dynamic.

Global level co-ordination and implementation of projects.

Participate in the creation of technical product specifications, prototype design, test plans, FEA and drawings.

Cost Analysis and implementation of innovative methods to reduce costs.

Implementation of new cost effective plastic processes like Gas Assisted Molding, Rapid Heat & Cooling Molding Technology, Microcellular Foam Molding, Extrusion foam molding,etc.

Implementation of plastic finishing technologies like Film Insert Injection Molding, Infused printing, Water Transfer Printing & Molding with Metallic pigments.

Process Selection based on Product – Injection Molding, Structural Foam Molding, Gas Assisted Molding, Thermoforming, Extrusion, Blow Molding & Rotational Molding.


University of Massachusetts, Amherst, MA – GPA 3.5/4.0

Master of Science in Mechanical Engineering (MSME) with Plastics Engineering

S.P. College of Engineering, Bombay University, Bombay, India

Bachelor of Engineering (BE) First Class with Honors


Polymer-Plastic Technology and Engineering," A New Approach to Low Thermal Inertia Molding"

Plastics West-SPE/SPI Conference, Las Vegas, "Experimental Results of Low Thermal Inertia Molding"


09/12-14/06, Invited as Keynote Speaker for 6th SPE Automotive Composites Conference

ANTEC 2006, Presented "Indian Plastics Industry" at plenary session, Charlotte, NC

Presented technical papers at many Conferences on Gas Assisted Molding / Two Platen Injection Molding.

Provided Training to Faculty at CIPET on Gas Assisted Injection Molding Technology


Professional Technical / Management Courses Attended:

Six Sigma DMAIC Black Belt Training, Samsung SDI, Group

4dx Leadership Training

Problem Solving & Decision Making

Plastics Part Design – Injection Molding Paulson

Industrial Blow Molding, IDA Associates, Inc.

Moldflow® Release 7 Training, Moldflow, Inc.

Mold Design Hoechst Celanese - Design Training

Plastics Design Workshops and Lectures, PDF

Finite Element Analysis Seminar, CAE Associates, Inc.

Selling Skills, Conrad Associates, Inc.

Ultrasonic Assembly Technical Workshop, Branson

Experimental Design, Introductory Course, HCC

Plastic vs. Metal: The Material Difference, SAE

Plastic Part Design For Economical Injection Molding, GB

SPC Techniques, IBM Corporation

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