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Power Plant Manager

Pune, Maharashtra, India
March 31, 2021

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Core Competencies

Profile Summary

Plant & Manufacturing Operations

Production Engineering & Operations

Quality Assurance & Control

Delivery Management

Product Development & Improvement

Auditing & Compliances

Budgeting/ Cost Optimization & Control

Process Engineering & Improvements

Operations & Maintenance

Logistics & Dispatch

Resource Optimization

Vendor Development



Technical Skills

MS Office

SAP, M1, Oracle ERP


MS Project

A competent & result-oriented professional with an effective experience in devising significant solutions, managing day-to-day Production, Maintenance, Manufacturing Excellence, Safety, Quality Assurance, Dispatch activities with focus on top & bottom-line profitability by ensuring optimal utilization of 5 M (Man, Machine, Materials, Method & Money) & QCDMS (Quality, Cost Delivery, Morale, Safety)

Proficient in Machining, Fabrication, Assembly and Powder Coating; skilled in conceptualizing and implementing process initiatives to enhance efficiency and productivity; worked in Machine manufacturing, Car OEM, Furnace manufacturing, Industrial gear box manufacturing, Conveyor Automation, Poultry farm equipment manufacturing

Highly resourceful in Quality Management System (ISO 9001-2008) including internal audits, Process & Supplier audits and recommending & implementing corrective and preventive actions while ensuring in-process quality control and continuous improvement in process capabilities

Certified Lean Six Sigma Black Belt (LSSBB); implemented measures for enhancing the process capability index of machined & fabricated parts maintaining the USL & LSL limits in smooth running of the plant; skilled in instituting quality assurance practices to achieve business excellence at the lowest overall cost

Proficient in implementation of lean manufacturing by calculating Takt time, Buffer stock, material supply frequency

Possess competency in localization of parts by vendor development, outsourcing, technically advising & guiding vendors to meet desired standard and targeted price

Experienced in working in multicultural environment having nationals from Europe, America, Far East, New Zealand & so on

Insightful knowledge in formulating and administering company policies, directing and coordinating all department activities to develop and implement long range goals and objectives

Showcased excellence in setting up green field project for Glidepath (Fabrication & Machining facility), Rieter (Fabrication facility) and Fiat (Industrial Engineering)

Insightful skills in driving process improvement by implementing Lean Manufacturing, WCM, Kaizen, 5S Concepts, Multi-Skilling Concept, Value Stream Mapping, TQM, TPM activities; debottlenecking &process standardization for productivity & quality improvement; minimized the breakdowns of plant machines & equipment through analysis of breakdown & preventive measures

Proven track record in coordinating, planning and implementing changes to technology, machinery and process methodology, direction of quality assurance and control systems & reporting procedures; implemented systems such as ISO-9001-2008 and achieved the highest manufacturing excellence through TQM like ‘World class manufacturing’

Comprehensive understanding on the concepts of Value Analysis/ Value Engineering, Vendor Value Analysis and Selection, Breakdown Management, Internal Audits, Field Failure Analysis & Troubleshooting

Exhibited a strong and firm approach to sustain and encourage safe work environments, and capabilities to streamline operations; applied continuous improvement principles to increase process and maintenance efficiency and company profits NIRMALYA SENGUPTA

Head of Operations with chronicled success of 24 years in driving organizational growth, targeting senior level assignment in Production, Maintenance, Quality, Operations Management with an organization of repute +91-982*******

Career Timeline

Jul’ 03 to Apr’ 07 May’ 07 to Dec’ 10 Jan’ 11to Aug’ 17 Jan’ 18 to Jul’ 19 Aug 2019 to Present Work Experience

Aug’19 to Present: Metplast Industries Ltd. (Under Kishorefarm) as Operations Head Poultry Farm Equipment manufacturer, Mumbai based company Jan’ 18 to Jul’ 19: Glidepath India Pvt. Ltd., Pune as Manufacturing Head Airport Baggage Handling System Manufacturer, New Zealand based company Jan’ 11 to Aug’ 17: Rieter India Pvt. Ltd., Pune as Manager (Manufacturing Engineering) Textile Spinning Machine Manufacturer, Switzerland based company May’ 07 to Dec’ 10: Fiat Automobiles India Pvt. Ltd., Pune as Deputy Manager (Manufacturing Engineering) Car OEM, Italy based company

Roles Across The Career:

Spearheading operations functions heading Production, Maintenance, Logistics, Dispatch, Quality & Systems; managing a sheet metal facility & machining facility of a poultry battery cage system manufacturing unit having nearly 200 employees and accountable for a yearly target of 150 Cr INR

Administering entire gamut of production activities on fabrication & machining, PPC, Stores, Packing & dispatch, Quality department, HR, Facility, Maintenance & so on

Acting as a Single Point of Contact between directors and entire operation facility and liaising with the customers

Managing various machinery & equipment such as Laser cutting machine, Press brake machine, Turret punch machine, Roll forming machines, all welding facilities, CNC turning & milling centers, Powder coating plant

Spearheading various activities pertaining to Sheet metal fabrication, Industrial Engineering activities, Lean manufacturing implementation in sheet metal shop floor, Order fulfillment, Final Packing, Dispatch, Warehousing & so on

Assuring that the assigned tasks are executed as per conformance with approved quality guidelines for achieving highest quality & excellence standards

Appraising the prevalent manufacturing systems/ processes, identifying loopholes if any and undertaking result-oriented measures for alleviating them and documenting the same

Deploying various methodologies to analyze various processes, recommending modifications to minimize escalations, reduce rejection, realize operational efficiencies, control variability, costs and reduce cycle-time

Devising & implementing production strategies/plans in order to achieve the organizational production goals

Modifying equipment, process flow & working practices for controlling & reducing conversion cost per unit produced, ensuring optimum utilization of the available manpower/machinery

Monitoring quality systems & compliance with preset standards; troubleshooting and maintaining requisite documents to ensure complete in-process quality & improvement in process capabilities

Finding vendors/suppliers of MS & SS Fabrication that includes laser cutting, bending, powder coating & so on, vendors for machined parts like pulleys, Zn plating, fasteners, bearings

Performing Material Requirements Planning (MRP), Material availability check and converting planned order to production orders

Inspecting material quality received from vendors/ suppliers to ensure adherence to quality standards & norms

Appointing suppliers for raw materials like pipe, MS/SS/GI sheets by acquiring in-depth knowledge in powder coating, fabrication, machining & so on to convince suppliers to meet the targeted cost

Monitoring purchase & installation of machines required for sheet metal fabrication plant like CNC Laser Cutting, CNC Press Bending Machines, CNC Roll Forming Machine and MIG Welding Stations & so on

Recruiting Assistant Managers, Supervisors & Operators

Analyzing the training requirements and delivering required training to the Engineers/Supervisors in the department; ensuring employee occupational safety, health and training program for production and maintenance personnel

Driving a culture of performance & safety within plant, managing production of daily / weekly / monthly targets in line with customer specifications, meeting all quality and safety standards

Incorporating maintenance schedules and conducting periodic checks to ensure performance of various equipment and maintaining requisite documents for the same

Minimizing the areas of bottlenecks & breakdown; taking steps to achieve zero accident & customer complaints through continuous monitoring and application of tools like root cause analysis

Managing 150 people including assemblers, machine workers, front line supervisors & middle level managers as a production in-charge of an Industrial Gear Transmission Manufacturing Unit

Acquiring in-depth knowledge in CNC machining using HMC, VMC, Turning centre, Hobbing machines, Bore & Cylindrical grinding machines, Thread & Gear grinding machines and also in Heat treatment operations

Resolving customer complaints on dispatch and setting-out quality standards for various operational areas and ensuring a high-quality customer experience while adhering to SLAs

Wesman Engineering Pvt.


Rieter India Pvt. Ltd. Metplast Industries Ltd.

Fiat Automobiles India Pvt. Ltd.

Glidepath India Pvt Ltd.

Computing TAKT time buffer stock, frequency of material supply to final assembly line from store & shop floor production centers, minimum batch quantity by designing & manufacturing a unique cart for material transport that may carry up to 250 kg of material

Conducting yearly appraisal of Assistant managers, supervisors & operators to fit their performance within a bell curve

Maintaining entire production related reports, material procurement plans and work delegation schedules (weekly & daily) for completion of production process


Rewarded with the Managing Director’s Award on successful completion of green field project to set up the 1500 Square Mtr. Sheet Metal Shop with Powder Coating Plant, Laser & Bending Machines & Welding Stations

Effectively achieved inventory reduction from 90 to 4 days by implementing lean manufacturing, amounting an inventory level reduction from 30 Cr to 1 Cr INR ; designed & manufactured material transport trolleys and calculated necessary buffer stock, material supply frequency and so on

Actively contributed to continuous improvement & cost reduction by introducing ‘employee suggestion scheme’ and achieved a cost saving up to 1 million USD (i.e. around INR 5 Cr.) in a year

Transferred comber assembly line from China plant & set up of assembly line for Comber & Drawframe machines in Indian plant

Created work centers & routing in SAP; allocated manpower & work distribution; Calculated OEE, Labour Productivity and successfully developed jigs & fixtures

Eliminated wrong supply & short supply completely by introducing & implementing line packing concept

Notable success in spearheading final packing that needed more than 50 boxes weighing 500Kg to 1 Ton each to be sent with every final machine; led Dispatching functions entailing loading & unloading of very heavy packing materials in containers and Warehousing those Previous Experience

Jul’ 03 to Apr’ 07: Wesman Engineering Pvt. Ltd., Kolkata A furnace manufacturer having collaboration with IPSEN Germany Growth Path:

Jul’03 to Jun’05: Asst. Manager (Production Planning & Control) Jul’06 to Apr’07: Asst. Manager (Production Planning & Control) Jul’ 05 to Jun’ 06: Net Guru Systems Ltd., Kolkata as Estimator Prepared BOM for HVAC and Plumbing Systems

Dec’ 95 to Jun’ 03: Premium Energy & Transmission Ltd. (Formerly M/s Greaves Ltd.), Kolkata as Sr. Engineer (Production) Industrial Gear Box Manufacturer


Hands-on expertise in running various machines such as Hobbing machine, Gear grinding machines, CNC Turning centers, CNC & manual Horizontal machining centers, CNC & manual Vertical machining centers, Worm thread grinding machines, Worm thread generating machines, Bevel generator machine, Heat treatment

Freelance Experience

Sep’ 17- Jul’18: Freelancer (Operation Management), Pune Highlights:

Successfully applied multiple tools such as Value Stream Mapping (VSM), Makigami for Process mapping

Used Lean tools such as Gemba, Muda, SOP, Work Place Organization & so on to attain an uninterrupted flow of CVs, JDs, technical documents for targeting 50% increase in business

Trainings Attended

Trained in Design Software like Unigraphics NX6, AutoCAD 2005, and Catia V.5 knows CNC Programming with Sinumeric & Fanuc Control

Production Planning Module of SAP, Oracle Apps & M1, trained in Oracle & Developer 2000

International Exposure:

Fiat Group Automotive, Turin, Italy

Training in Automobile Engine & Transmission Plant on Manufacturing Process & Machining Procedure of different parts Trained on Methods for Time &Motion Studies and on World Class Manufacturing (WCM) in Fiat’s different plants in Turin, Italy

BJC Construction Industries Ltd., Rayong, Thailand Worked as an Estimator to estimate the material requirement and man-hour requirement for power plant equipment

EMO Hannover, Germany

Attended 2011 EMO to purchase a new HMC machine from Mori Seiki

Rieter, China

Technically studied entire Combing Machine Assembly line in Rieter China & transferred the assembly line in India Education

B.E. in Mechanical from National Institute of Technology Silchar (formerly REC) with 71.53% marks (first division) in 1994

Distance Post Graduate Diploma in International Trade Management under NMIMS (Narsee Monjee Institute of Management Studies), Mumbai, with 65.67% marks (first division) in 2015 -2016


Certification course on Lean Six Sigma Black Belt (LSSBB) in 2018

Certification by DNV for Internal Quality Auditor Ship on ISO 9001:2008 and ISO 9000:1994

Obtained Chartered Engineer (India) Certificate in 2003

On the job training on World Class Manufacturing (WCM)

On the job training on Time & Motion Study, MTM-UAS Personal Details

Date of Birth: 22nd September 1972

Languages Known: English, Hindi, Bengali, Marathi, French Address: Flat No. 307, Tower 4, Gera Sky Villa, Kharadi, Pune- 411014, Maharashtra

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