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Manager Plant

Hyattsville, Maryland, United States
November 14, 2017

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Address: ****, ****** *****, *********, **. 20770

Phone: +1(443)***-**** Email: SUMMARY

Location : Greenbelt, MD. 20770

Position Held : Exe Vice President (O)

Marital Status: Married

Green Card Holder USA

Senior Management Plant/Operations Head Deliverables of Manufacturing Operations Parameters Ceramic/Building Materials Industry


An accomplished & hard working professional offering over 27 years of experience mainly in manufacturing sector with expertise in Production, Manufacturing, Operations and New Projects.

Possess 4 year Diploma in Ceramic & Glass Technology

Possess extensive experience in production planning & control, manufacturing, maintenance (Preventive & Proactive), process enhancements, quality & compliance management and cost optimisation.

Excellent knowledge in maintenance planning for total productive maintenance, skilled in utility maintenance, material handling equipments maintenance & maintenance of plant engineering equipments.

Providing assistance for different problem solving projects, analysis for different problems of the organisation for identification of statistically significant causes.

Leadership capabilities to manage team/people (Team Size up to 600+) with ability to hire, train & guide team members for gaining optimal productivity & performance.

Ability to envision and create successful teams with latest knowledge & modern skills in quality assurance and product development fields to deliver quality services.

Have expertise in enhancing production operations by optimising resources & capacity utilisation thus escalating productivity & operational efficiencies, curtailing cycle time, reducing rejection levels and thereby curbing costs.

Deft in implementing cost saving measures to achieve reduction in terms of effort, cost and time.

Target & achievement oriented with an ability to take up challenges & perform in changing work environments.

Possesses excellent interpersonal, analytical and negotiation skills with proven track record of utilising a process-oriented approach towards the accomplishment of cost, profit, service & organisational goals.

Visited Tunisia, Italy, South Africa, China, Turkey, Kazakhstan, Spain, UAE and Saudi Arabia for various technical, machines study & finalisation, opportunities exploration, alternative sourcing, productivity & process improvements and market studies.


People/Team Management ■ Process Engineering & Improvement ■ Plant Operations Management ■ Quality Control & Assurance ■ Strategic Planning ■ Performance Standards ■ Production Management ■ Quality Control & Assurance ■ New Systems Implementation ■ Analytical & Problem Solving


Executive Vice President ( Operations ) Since : Dec-2016 X Ceramics ltd, Bangladesh.

Head of Entire operations for Walls & Floors Ceramic tiles. In charge of 130 million US$ delivery

Al Anwar Ceramic Tiles Co. SAOG, (Al - Shams: Brand), Muscat, Oman Plant Manager Apr 2010 - May 2014

Reporting To: Managing Director

Production Manager Jan 1998 - Sep 2005

Reporting To: General Manager

Led a cross functional team of 30 Managers and 300 Operators in various plants. Apr 2010 - May 2014 &

Jan 1998 - Sep 2005

Served as an In-charge of the Complete Manufacturing Operations & Maintenance and Projects of the following: Wall Tiles Manufacturing Plant - 1 (9,000 M2/Day – SITI Machinery). Floor Tiles Manufacturing Plant - 2 (10,000 M2/Day - Sacmi Machinery). Floor Tiles Manufacturing Plant - 3 (11,000 M2/Day – Sacmi Machinery).\Wall Tiles Manufacturing Plant - 4 (12,000 M2/ Day – Sacmi Machinery).

Cost reduction initiatives on continuous basis to enhance the organization to become more competitive 2014: OR 521,250 savings under implementation.

2013: OR 311,340 savings.

2012: OR 329,898 savings.

Major Projects (Since Jul 2013):

Plant - 5 Expansion: 12000 SQM/day.

Plant - 3 Wet Grinding to Dry Grinding Conversion (To overcome Natural Gas shortage problem to Plant – 5). In-charge for ensuring the Repair & Maintenance cost under the budgeted levels.

In-charge for implementation of Lean Management Practices.

In-charge for Safety & Upkeep the Plant.

Acted as a Management Representative for ISO 9000 Certification.

Set-up the Plant - 4 in record time of 1 week & optimised the plant production to 12000 SQM/day within a month in 2012.

Improved the quality from 69% to 82%.

Successfully reduced machinery down time for all the plants - from 60 hrs/month in 2010 to 35 hrs/month in 2012.

Effectively installed Dry Grinding Technology of (LB supply) in 2012 (600 mt/day).

Optimised the Emended Plant - 3 and the quality to 11000 SQM/day from 9800 SQM/day in 2011.

Enhanced the plant capacity utilization (Installed Capacity: 2 Million M2) from 71% in 1999 to 138% in 2004.

Involved in improving the quality standards as 1st Grade Quality from 89.1% in 1999 to 93% in 2004.

Brought down process rejection rate from 10.5% to 2.2% in 2004 in the pressing to Packing Department.

Reduced annual machinery downtime from 588 hours to 149 hours in 2003.

Attained cost savings pertaining to Direct Variable Costs (USD per M2) to the tune of USD 0.32 during 1999 to 2004.

Augmented Clay Ball Mills capacity to 60% and reduced Glaze Pick-up Weight by 15%.

Significantly contributed towards turning around the loss making unit into a profit centre (loss of USD 117,270 in 1999 to profit of USD 3,325,000 in 2004).

Transformed body preparation process from Wet Grinding to Dry Grinding Technology. Actively involved in implementing a system to resolve customer complaints Received Chairman’s Award including Cash Reward in 2003.

Jet Granito Ltd, Rajkot, India

Plant Manager - Operations

Reporting To: Managing Director

Apr 2007 - Mar 2010

Successfully implemented the plans for established Green Field Plant for 6000 sqm/day vitrified tiles plant. Ensured stabilisation of the plant and operations within time and quality parameters. H & R Johnson (Sentini), Vijayawada, India

General Manager – Operations

Reporting To: Managing Director

Feb 2006 - Feb 2007

Played a pivotal role in enhancing the plant capacity by 28,000 sqm/day by optimizing & establishing the Line - 2 with B&T technology within a weeks’ time.

Increased the Spray Drier output from 18 ton/hour to 25 ton/hour.

Addressed the natural gas shortage problem by establishing coal based hot air generator Eid Parry (I) India Ltd, Pondicherry, India

Senior Executive – Production

Reporting To: Plant Manager

Manpower planning and carried out troubleshooting initiatives for quality & volumes. Coordinated with quality and lab and managed maintenance functions. In-charge for PPC.

Modi Champion Ltd, Alwar, India

Assistant Manager – Production

Reporting To: General Manager

Jan 1995 - Dec 1997

Jun 1993 - Dec 1994

Worked as Project Engineer for implementing Spark-plug Project with Champion Co. (USA) technology. Metlex Ceramics Ltd, Gurgaon, India

Superintendent – Production

Reporting To: Production Manager

Jun 1989 - Oct 1993

In-charge of the day today production, trouble-shooting & quality targets for Body Preparation and Firing Department. Spartek Ceramics India Ltd, Tirupati, India

Supervisor – Production

Reporting To: Technical Manager

Worked as production supervisor for Body Preparation, Firing and Classification Department. Jul 1986 - Jun 1989


Underwent Safety Training Program - EHS in Japan, 2015.

Underwent 1 Week Training Program for Lead Quality Auditor with BVQI in Muscat, 2005. Attended Technical Training (Sacmi Machinery) in Italy, 1995. KEY PERFORMANCE AREAS

Plant Planning Activity

Planning plant activities; implementing plans with a view to ensure smooth running of plants and timely accomplishment of targets within the cost parameters.

Implementing effective techniques to bring efficiency in operations to improve quality standards & achieve maximum cost savings. Operations & Process Management

Heading operations ensuring timely accomplishment of production targets within the time and cost parameters.

Taking stringent quality measures, including preparation of necessary documents (Process Control Plan, Manufacturing plans) to ensure compliance with standards & requirements.

Identifying areas of obstruction/breakdown, taking steps to rectify through application of trouble shooting tools. Resource & Quality Management

Implementing quality standards and structured processes / quality plans for Equipment & Machinery.

Monitoring & optimising processes, troubleshooting problems in coordination with other departments and improving efficiency.

Designing and conducting capability building programmes for operator/fitter, aligned with the future operational objectives and the need of the functional departments.

Environment, Health & Safety

Ensuring adherence to Safety, Environment and Health standards in all functional areas and developed & implemented measures for enhancing EHS levels.

Developing on site emergency plan for ensuring safe and accident free operations and installation & maintenance of safety equipment/measures.

Conducting various studies.


Ensuring document control and implementation according ISO 9001 & ISO 22000.

Preparing and reviewing Standard Operating Procedure (SOP), Operation Log Sheet Formats, etc. Team Management

Directing and leading the team towards attaining the target.

Assigning individual targets and tracking progress by analysing daily reports.

Imparting on job training to workforce for accomplishing greater operational effectiveness and efficiency. COMPUTER KNOWLEDGE

Well versed with MS Office Suite – Word, Excel & PowerPoint, E-mail applications and the Internet. EDUCATION

GOVERNMENT CERAMIC INSTITUTE, Andhra Pradesh, India 4 Year Diploma in Ceramic & Glass Technology 1985


Available on request.

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