PRATHMESH KHAIRNAR

Operational Excellence Manager

+91-883*******

adzagn@r.postjobfree.com

http://linkedin.com/in/prath

mesh-khairnar

in

• A detail-oriented industrial engineer with nearly 6 years of experience in delivering solutions that remedy business operational issues and position the organization to reach the next level of profitability through technology introduction and more efficient production processes

• Expertise in designing and planning production layouts, processes and schedules that increase productivity, eliminate wastefulness and reduce costs while maintaining quality standards within an organization

• Generated unique or leading-edge solutions and embraced new ideas that helped sustain business and optimized value stream implementation projects with the focus on continuous improvement of Safety, Quality, Delivery & Cost

• Used data analytics, data visualization and data modeling techniques & technologies to figure out market and business trends that helped the management to modernize and improve processes in the industry and increase profits and efficiency

• A project planner with expertise in planning, executing and spearheading various projects with competent cross-functional skills while ensuring on-time deliverables within preset cost parameters and resolving day-to-day problems

• Well versed with Scrum framework by emphasizing on teamwork, accountability and iterative progress toward a well-defined goal and can work as servant-leader, facilitator, coach, conflict navigator, manager, mentor, teacher, impediment remover, and change agent

• Led improvement initiatives and Business Excellence Process Simulation through Six Sigma, TPM, OEE, Autonomous Maintenance and Lean Manufacturing using KAIZEN, KANBAN, 5S, 7 QC Tools and 7 Wastes

• 2018: M.Tech. (Industrial Engineering and Management), 8.67 CGPA National Institute of Technology, Tiruchirappalli (NITT)

• 2014: B.Tech. (Production Engineering), 6.83 CGPA College Of Engineering, Pune (COEP)

MS Office Suite, MS Project

Power BI, Qlik Sense, Minitab,

Smartsheet

SAP, ERPNext, Oracle

AutoCAD, Power Apps

FlexSim, Sharepoint

Communicator

Analytical

Collaborator

Problem Solver

Leader

Lean Six Sigma Green Belt (LSSGB)

Supply Chain Operations

MS Excel Beginner to Advanced

Data Analytics Through R Programming

PMP (Pursuing)

Apr’2015 –

Jul’2016

Manufacturing

Engineer

LG Electronics

India Pvt. Ltd.

Jul’2018 –

Aug’2020

Production

Engineer

VKL Food

Solutions

Enterprise

Jan’2021 -

Jan'2023

Business

Excellence

Engineer

UPL Limited

Feb’2023 -

Present

Operational

Excellence

Piramal Pharma

CAREER TIMELINE

EDUCATION

PROFILE SUMMARY

CERTIFICATIONS

SOFT SKILLS

TECHNICAL SKILLS

Production Planning & Control

Project Management

Process Engineering & Improvement

TPM/ Kaizen / 5S Implementation

Supply Chain Management

Lean Manufacturing and Six Sigma

Data Analysis & Visualization

Process Simulation and Optimization

Business / Operational Excellence

CORE COMPETENCIES

Enterprising leader & planner with a strong record of contributions in streamlining operations, revive businesses, heightening productivity & procedures, targeting challenging assignments in Industrial Engineering, Supply Chain Management and Project Management with an organization of high repute for mutual growth and success

Location Preference: Maharashtra, West India

Operational Excellence Manager Feb’2023 – Present

Piramal Pharma Solutions, Indore

Responsibilities:

• Driving the operational excellence framework at site with central team

• Site KPI digitization on Qlik sense dashboard for easy tracking and monitoring of the data

• Data collation, analysis and visualization for Yield, OEE and OPEX data for senior management review

• Managing, driving and improving the site KPI such as OEE, OTIF, COPQ, Yield along with CFT

• Project management for critical projects and guide team members on the improvement actions

• Capability building of the site employees on Lean, Six Sigma, VSM, 7 QC Tools, OEE and other relevant topics

• Sharing and gaining best practices and knowledge with global OE team leads

• Analyze the OPEX data, identify scope to work on the OPEX cost optimization initiatives and track project progress & savings

• Participate in internal and external forums in different competitions like Kaizen conventions, CII Business Excellence Engineer Jan’2021 – Jan’2023

UPL Limited, Ankleshwar

Responsibilities:

• Streamlining operations and improving process efficiency for achieving cost saving across the site in all areas; working with McKinsey on a productivity improvement project using Digital & Analytics

• Analyzing production and downtime data in order to determine and recommend further areas for improvement in the processes

• Leveraging use of Eliminate the Wastes (Muda), Failure Modes and Effects Analysis (FMEA), Value Stream Mapping (VSM) and other Lean Tools for process improvement/optimization

• Participate and implement TQM framework at site level with pillars like QCC, IM, DWM, Kaizen, AM Highlights:

• Planned, deployed and monitored productivity improvement and cost saving projects namely: o Statistical analysis of variability reduction using Minitab o Dashboard making using Power BI for export containers movement inside the unit o Changeover time reduction projects with Cross-Functional Teams (CFT) o Workforce rationalization projects (MOST technique for work measurement) o Existing and New process simulations with FlexSim for resource optimization o New warehouse design and warehouse expansion

• Spearheaded the Automation projects initiation and projects validation by Simulation

• Felicitated with SMED CII GOLD AWARD for reducing changeover time by 31% in Feb’2022 that reduced overhead cost & wastage and enhanced the revenue by increasing uptime

• Led productivity enhancement of the plant by Data analytics and Kaizen from 20TPD to 25TPD

• Achieved Export logistics cost reduction of 83 Lakhs per year by analyzing the stuffing data and optimizing the loading pattern in container Production Engineer (Senior Executive) Jul’2018 – Aug’2020 VKL Food Solutions Enterprise

VKL Food Solutions Enterprise (FSIPL), Pune ( Jan’2020 – Aug’2020) VKL Food Solutions Enterprise (VSPL), Alleppey (Jul’2018 – Dec’2019) Responsibilities:

• Entrusted with responsibilities of scrutinizing production/maintenance schedules, shutdown maintenance, quality strategies and directing the team for on-time completion of the allocated work

• Led, mentored and guided the team of 60 workers and officers while streamlining Production Planning and Manpower allocation for the efficient operation across all the 3 shifts

• Administered the operations and maintained optimum inventory for Beverages and Gravies at 3P while creating new and update existing Standard Operating Procedures (SOP)

Highlights:

• Acted as a training specialist; imparted trainings on 5S, Total Quality Management (TQM), Tool Box Talk to the teams in order to ensure quality and efficiency in the production department

• Spearheaded implementation of online metal detector to reduce NVA that saved the annual cost of INR 4.5 Lakhs

• Designed, trained, and implemented Autonomous Maintenance and 5S auditing system in 11 areas of the Plant to improve plant organization and housekeeping

• Strategized new layout planning for process improvement that enhanced efficiency by 10%

• Displayed production excellence by achieving First Pass Rate (FPR) of from 95% to 99% and On Time In Full (OTIF) from 80% to 85%

• Improved the Overall Equipment Effectiveness (OEE) of the blenders from 50% to 60%

• Implemented CAPA for reworks and customer complaints after Root Cause Analysis (RCA) of the problem

• Conferred with Value Excellence Award for improving the blender productivity by 60% in Apr’2019 by analyzing CIP, Time Study (VA, NVA analysis), and Waste Reduction

WORK EXPERIENCE

Manufacturing Engineer (Senior Engineer) Apr’2015 – Jul’2016 LG Electronics India Private Limited, Pune

Responsibilities:

• Standard Time (ST) calculations for RAC and TV line by PMTS/MODAPTS for all the new products development or during process change

• Drafted and maintained Work Instructions (WI) and Quality Control Flow Charts for RAC and TV models for over 90 Models

• Conducted Time & Motion Study while performing Line Balancing by using STMS to avoid bottlenecks

• Led identification of VA/NVA activities on the assembly line and in worker’s motion

• Check new products development in terms of Design for Assembly (DFA) Highlights:

• Achievement cost saving of 2% in a cost analysis project for Air Conditioner (AC) by Benchmarking in a group task in coordination with Cross- Functional Teams

• Modified an assembly line using Poka Yoke (Mistake Proofing) that improved quality and improved productivity on the assembly line

• Ensured smooth flow of new product in Mass Production without line stoppage or failure or any defect by verifying drawings of the products and validating the BOM to get 100% accuracy in the production and Work Instructions

• Awarded Star Employee Award for achieving the standard time reduction by 1.4% in TV line by doing MOST work measurement in May’2016 Date of Birth: 14th September 1992

Languages Known: English, Hindi and Marathi

Address: Indore, Madhya Pradesh, India

PERSONAL DETAILS

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