SANJAY SHEVADE - SENIOR OPERATIONS LEADER

https://www.linkedin.com/in/sanjay-shevade-65318612

: +91-998******* : adlttg@r.postjobfree.com

PROFILE SUMMARY

A seasoned, success-driven and perseverant Senior Leader with over 3 decades of rich experience in providing strategic direction to the overall operational plans for large-scale manufacturing units operating within the domains of Food & Non-Food Category FMCG. Over the years have dealt with challenging and complex demands of handling business situations by developing and executing strategic operational plans, enhancing productivity and profitability through clear objectives and utilising business improvement principles along with KPI trending and analysis, thereby establishing a competitive position in the market. Possessing a powerful combination of leadership skills and functional knowledge, my expertise lies in working on lean operational processes to reduce cost, improve efficiency and quality, managing supply chain, ensuring compliance with applicable external regulatory standards and executing key transformation projects to meet the manufacturing excellence standards and deliver outstanding business results.

A team oriented leader, have successfully provided leadership to optimise organisation structure by building, managing, mentoring, and providing career development programs to attract, engage and retain professional talent, thus creating empowered work environments.

AREAS OF EXPERTISE: Strategic Planning & Implementation Operational Leadership Quality & HSE Management Budgeting & Financial Management Process Improvements & Efficiencies Manufacturing & Production Productivity Enhancement & Cost Optimization Supply Chain Management Lean Manufacturing Data-Driven Decision Making Cost reduction, Quality Improvement and De-bottlenecking Team Performance Management & Development Coach & Mentor Stakeholder Management

KEY CAREER ACHIEVEMENTS

Sectoral Expertise in FMCG and Non FMCG manufacturing, Supply Chain and Technical functions in Matrix organizations

Driving Cost Reduction & Optimization is a key strength in a manufacturing set-up

Successful in neutralizing inflation for many years in FMCG products like Fevikwik, M-Seal, Steel-Grip,Rin and Annapurna Salt through manpower reduction, energy efficiency and throughput increase.

Highly adept at leading critical projects to cater to the business requirements, streamline operations and improve overall process efficiencies

Spearheading & Transforming the operational processes to successfully survive and grow in fast-paced and highly competitive environments

Recognised and appreciated for the stakeholder relationship management and has been instrumental in managing syndication with various stakeholders to recommend enhancements and drive consistency

Played a key role in implementing change-related initiatives to drive strong process controls, low cost and relevent automation and increase the review effectiveness to deliver high standards of work

Effective in driving manufacturing excellence, deploying Root Cause methodology for analysis as a basic pre-requisite for accepting solutions and expenditure.

Management of Multi -site Manufacturing set-up and leveraging the distributed nature of the set-up

Strong managerial aptitude and business insight to structure business compliant supply chain organization

Strong sense of accountability and ownership with an eye on quality, best practices and growth opportunities

WORK EXPERIENCE

Sudarshan Chemical Ind. Ltd. Roha Site Mar 2020 – Feb 2021

(It is the leader in manufacture of Pigments in India & world’s fifth largest company in the Pigments. Roha site manufactures about 80% of the company’s volume. It houses 20 plants under various pigment chemistries like Azo, High Performance & Effects Pigments.)

AVP Operations, Roha

Responsible for developing and driving the implementation of short term & long term site operational management strategy and ensuring alignment of the functional objectives with the overall business goals. Commissioned the Solvent Based Dyes project and productivity improvement in Azo Plants.

Achievements:

Improved delivery performance by process improvement and through removal of bottlenecks: KPI Plant OEE - 87 % (2019-20) to 91 % (20-21) and KPI OTIF 77% (2019-20 ) to 83%( 20-21)

Achieved an improvement from 83% to 92% (20-21) in Order fulfilment rate for export orders through process enhancement.

Delivered Cost Savings of Rs 3 Cr annually in solvent Methanol Consumption through improvement of Solvent Recovery Plant Performance and optimization of solvent quantities used in batch making.

Reduction in Packing Labor cost by Rs 125/ton through technological improvement of self-breathing bags.

Pidilite Industries Ltd.

(It is an Indian adhesives manufacturing company. It also sells art material, construction chemicals and other industrial chemicals.)

Chief of Operations - ICA Pidilite Division, Jambusar Nov 2018 – Feb 2020

ICA Pidilite is JV between Pidilite and ICA of Italy. This is first factory of ICA outside of Europe. Pidilite was selling these products into India through some other channel partner till the factory was established. As a startup, appointed in charge of technology transfer from ICA for wood finishes based on Epoxy, Polyester and Melamine chemistry along with handling responsibilities for project startup including recruitment and commissioning

Spearheaded best-in-class manufacturing practices followed by ICA-Italy, implemented Management Systems (Q&HSE) Standards and established monitoring tools to ensure adherence to the standards.

Ensure compliance with statutory requirements mandated by Factory Directorate, PCB, Labour Dept., PF/ESI etc.

Supervised and ensured achievement of KPIs in terms of Productivity, Operating Efficiency, Rejection, Cost, and Service level. Ensured the discipline of periodic review of capacity to enable supply chain readiness at all times.

Drove efficiency improvements across plant functions including OEE, resources utilization, inventory turns, and capacity optimization.

Worked with R&D to bring about new products to freeze special demands to meet the special requirements of customers.

Implemented procurement policy and operational framework to ensure business compliant procurement process and work flow. Introduced Organization Excellence practices, and support key plant decisions on changes.

Managed local Labor Regulations, Business Ethics, issue resolution and sponsored diversity and inclusion in the site.

Coached manufacturing site leadership on how to integrate the company key measures with the department’s internal measures and determine the capability needed to deliver outstanding results.

Enabled manufacturing units to meet Supply chain targets e.g. weekly delivery indices, new products delivery, OTIF and Quality both for domestic & export markets.

Controlled RM and PM variances, process yields and Total Manufacturing Costs and initiated cost savings programs at Division Level. Planned Capex & Opex related to operations division, administered and managed budgets.

Achievements:

Successfully ramped-up of plant to 90% of rated capacity within 3 months of start-up

Technology Transfer from ICA -Italy: 60% volume of imported products made available for sale from the Indian factory within 6 months of plant startup and resulted in savings of Rs 0.8 Cr/ month.

Drove the project of replacement of European RM components with Indian alternatives with the products meeting European Standards. Achieved a Cost savings Rs 16 Cr annually.

Promoted the Cultural shift of people for adhering to the European Standards – GMP, Safety, Quality Assurance and Plant maintenance.

Chief of Operations – Consumer Products Division, Sep 2010 – Oct 2018

Responsible for entire operations of 7 company owned manufacturing sites and 12 medium sized job -working units, generating a business volume of INR 1300 Cr

Achievements:

Achieved 98% of OTIF on key product lines – Fevikwik, M-Seal and Steelgrip through effective supply assurance practices.

Achieved direct cost reduction of 8-10 % in Flagship -Fevikwik – absorbed yearly labor inflation for 5 continuous years from 2013.

Achieved an annual average cost reduction of 6% on operating costs on other key product lines through systematic application of cost reduction handles- Multilaning in packing machines, Layout changes for manpower reduction, Energy and Material Savings.

Through 5S initiatives and space optimization the new Capex Cost per lac units of Fevikwik reduced from Rs 20 Cr to Rs 12 Cr in 5 years.

PREVIOUS EMPLOYMENT HISTORY

General Manager (Private Labels) Reliance Retail Limited Apr 2008 – Sep 2010

(Led manufacturing outsourcing operations for own FMCG own brands with approx 50 vendors and successfully delivered the entire range of 20 private label products in the Processed Foods/Non-Foods category)

Factory Manager - Detergent Factory Hindustan Unilever Ltd (HUL) – Mangalore Oct 2007 – Apr 2008

(Delivered 20% growth in production volumes with existing facility and reduced production cost by 7% for low cost detergent powders through local sourcing of fillers. Implemented improvement initiatives like TPM, Kaizen and training programs)

Manufacturing Manager (Soaps) HUL Orai Factory Jun 2007 – Oct 2007

QA & Technical Manager HUL Foods Division Nov 2001 – May 2007

Unit Operations Manager HUL Salt Manufacturing Unit Jan 1995 – Nov 2001

Production Officer HUL Detergent Unit Nov 1989 – Dec 1994

ACADEMIC QUALIFICATIONS & CERTIFICATIONS

oB. Tech (Chemical Technology) from HBTI Kanpur 1989

Professional Development

oExecutive Development Program, IIM Kozhikode 2003 – 2004

oAPICS – Certified Supply Chain Professional from The Association for Operations Management, USA 2008

Trainings & Events

oAPICS CSCP- 2007, Mumbai

oSix Sigma Green Belt - 2017, Mumbai

oMOST technique for Manpower Efficiency - Accenture

oWorkshop on IOT - Microsoft

oWorkshop on Behavioral Safety – DuPont (Certified Trainer on Behavioral Safety)

oWorkshop on Foods HACCP – HUL

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