Manufacturing Excellence Systems

PREM PRAKASH KUSHWAHA

Highly seasoned Plant Manufacturing - Operations Professional

An seasoned human offering chronicled the success of + Two Decades of experience in all aspects of E2E Plant Operations.

High calibre and result driven manufacturing professional with hands on and accomplished career of 28yrs in Brewery, FMCG, Packing/Bottling, Foods & Snacks, Agro Foods, Cosmetics And Chemicals In Manufacturing, Engineering, Projects and Manufacturing Excellence. Expertise in leading large and mid-size manufacturing and engineering operation demonstrating year on year improvement in PQCDSM with strong and decisive leader capable of managing and fostering excellence in varied industrial climate and change management. Proactive, analytical and achievement oriented professional championing manufacturing excellence philosophy based on TPM, lean, TQM, six sigma and superior performance through effective communication, coordination, strategizing, planning and execution. ********@*****.*** +91 – 638-***-****

Linkedin: https://www.linkedin.com/in/prempk122/

CORE COMPETENCIES

CAREER TIMELINE

SOFT SKILLS

ACADEMIC CREDENTIALS

Future Aspirations :

Senior level assignments viz Head Manufacturing Operations, with Plants Expansion Initiatives, Driving Manufacturing Excellence.

Result Oriented professional with over Two Decades of hand on experience in the above-said roles PROFILE SUMMARY

Profits: Top & bottom-line profitability by ensuring optimal utilization of resources.

Resource Optimization: Overall power, Utilities, Process losses & material wastages.

Procurement: Development in New sources for raw materials.

Liaising: Liaised with key Government departments / Agencies.

Compliances: Ensured on-time compliances related to all Government departments

Certifications: Du Pont Safety course, SHE Pillar by CII; Advance Problem-Solving Skills & TPM Trainer

Project Management: Planning, Scheduling, Costing- Estimating, & Monitoring.

People: Successfully implemented Rewards & Recognition schemes at all levels

Commercial: Costing, Budgeting, Reports preparations, Assets Management and Inventory.

Projects: Erection, commissioning and operations of green field and brown field plants. WORK EXPERIENCE

Head – Plant Operations (DGM Works) with BMMIL, NCR, Haryana since Nov’ 22 – Mar’24 Role:

Safety and EHS:

Ensuring Environmental, Health and Safety standards and procedures are adhered to.

Ensuring “Zero fatality”, “No violation of Safety” and “No violation of PPEs”

Focus on Leading & Lagging Indicators for Zero Accidents.

Adherence to all Safety regulation Procedures & KPI reporting. Quality:

To achieve zero customer complaints through continuous monitoring & RCA Application.

Reducing market complaints by establishing strict quality control measures

Instigated systems for the earliest complaint resolution. Cost:

To reduce Variable cost by through raw materials, energy alternatives & energy projects.

Controlling cost by better spares management and process optimization. Productivity:

Executing excellence in production for Plant smooth functioning.

Identification of bottlenecks & breakdowns to achieve on-time maintenance across plant.

Managing all raw materials, packaging material, manpower, and required spares

Leveraging cost controls, scrap amount reduction and lean manufacturing. Delivery:

Ensuring timely dispatches, as per Business Goals

Developing new vendors and contractors to make sure well-timed execution of the jobs Liaisoning & CSR :

Approvals and validation of products and packs as per business and government guidelines.

Effective liaising with statutory and regulatory agencies.

Sustainability development road map involving Energy, Water & Carbon footprint reduction, Projects, Capability development

Leadership and Manning:

Providing leadership, coordination and coaching to the team.

Developing and ensuring a high performing and high engagement work culture and teams. Strong Collaborator

Decision-maker

Strategic Leader

Planner & Thinker

BMMIL, (NCR, Haryana)

Dayal Industries Ltd., (Lucknow)

JK Organization, (NCR, Delhi)

ASDC, Udaipur, Rajasthan

OLAM INTERNATIONAL,

SAB MILLER, Aurangabad (MH.)

PepsiCo India, Panipat (Haryana)

Engineering/ Mfg. Operations

Organizational Development

Quality, SHE, ISO and OSHAS

Strategy Planning

Continuous Improvement, WCM

Business Excellence

Process Development

Process Standardization

SAP & ERP Implementation

Project & CAPEX Management

B. Tech (Mech Engg.) – 75% (Hons.) HBTI,

Kanpur – 1995

Advanced diploma in Management - AIMA,

N. Delhi – 1998

12 Certificate courses in management -

Gyanodya, Bombay – 2004

Achievements:

** PRODUCTIVITY

Increase in plant utilisation through engineering practices from 40% to 89% - [2016 – 17]

All time highest aqua feed production by improving plant utilisation from 70% to 85% - [2021 – 22]

Maintenance Improvement – 57% in MTBF & and 26% reduction in MTTR – [2016 – 17]

Improved plant utilisation over the previous year by 15% - 2021 – 22]

Increased plant capacity utilization from 60% to 80% & Scrap reduction 11% to 2%. – [2009 – 10]

** SAFETY

Formulation and implementation of SHE activities and reporting’s [2015 – 17]

Zero accidents and won various internal and external prestigious award for safe working – [2016 – 17]

Reduction in non-LTA accidents in operations by 28% - [2021 – 22]

** PROFITS

Turnaround in EBITA for manufacturing from -2% to +8% [2018-19]

Saving through engineering improvement activities Approx of 179,000 USD [2017 – 18]

Reduction in overhead cost by 15% [2020 – 21]

Reduction in production cost by 10 % with 12% reduction in energy cost [2021 – 22]

Reduction of departmental expenses from 1.95 lacs / month to 1.1 lacs/ month (IRIL) [2001 – 02]

Reduction in energy consumption by 18% YOY [2016 – 17]

** PEOPLE

Implementation of Rewards and recognition scheme [2021 – 22]

Implementation of small working groups -Gyanyodya [2020 – 21]

Manpower optimization by 21% [2004 – 05]

First coach in SABI (Mentor) for grooming the new recruited / positioned Pkg Managers. [2012 – 13]

** PROJECTS

Vertical construction and start-up of greenfield / brownfield factory (45Cr) [2020 – 21]

Commissioned full plant in record span time. (35Mn USD) [2015 – 16]

Vertical start-up of greenfield factory at Bihar (5 Cr) [2021 – 22]

Stellar role in successful launch of first PET beer in Asia from newly commissioned line [2011 – 12] PREVIOUS WORK EXPERIENCE

Cluster Head - General Manager (Operations - Work) – Dayal Industries Limited, Barabanki, U.P & Muzaffarpur, Bihar Aug’21 – Nov’22

Works Head (DGM) - JK Organization (TFPL), NCR, Delhi Jun’19 – Aug’21

Assistant General Manager (O&M) - Heading all 8 manufacturing Plants in India May’18 – Jun’19

Head of Maintenance – Olam International Jun’15 – May’18

Sr. Manager – Engg / Mfg.– Heading for 2 Units – Pals & Foster – SAB Miller India, Aurangabad (Maharashtra) May’07-Jun’15

AM-Manufacturing / Engineering / TPM - PepsiCo India, Panipat (Haryana) Nov’05 – May’07

Engineering Officer – All India cadre - Hindustan Lever Ltd, Orai, UP Apr’04 – Nov’05

Head of Department – Engg. - Indian Rayon, (AV Birla), Veraval, Gujarat Jun’95 – Apr’04 TRAININGS & CERTIFICATIONS

Internal Auditor – ISO 9000,

Internal Auditor – ISO 14000

Internal Auditor – ISO 18000

Internal Auditor – ISO 22000

IMS

TPM,

MWay & WCM,

OSHAS

Asset management & investment care

Condition based monitoring systems and

RCM by IIPM

Lean Management Systems - Kaizen, 5 S

Performance Management

Leadership Development Workshop

PERSONAL DETAILS

Personal : Married (Wife Doctorate & 2 Children)

Notice period : 30 days (Negotiable)

Linguistic Skills: : English, Hindi, Gujarati, Marathi

Passport : Available

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