Process Engineer Processing Specialist

CURRICULUM VITAE

SHRIKANT KALE

Plastics Processing Specialist

**** ******* ****

Riverfalls WI 54022 (USA)

E-mail: ****.*******@*****.***

Mobile No (USA): +1-402-***-****

OBJECTIVE:

Wishes to use my 17 years of Experience and education (Bachelor’s Degree in Chemical science, Post Graduate in Plastics Technology, and MBA in Production Management) & Good Experience of Plastics a.k.a Polymers processing for Packaging and related Industries including their Operations, Quality, and Technical services by serving my best throughput to organization and human beings.

PROFESSIONAL SYNOPSIS:

A Plastics Processing Specialist with good experience in Production/Processing Operations, Quality Control, Technical Services & product development in Plastics flexible packaging and related chemical industries.

Specialized in handling overall Plastics processing machines, Raw materials selections, Material Formulations according to Chemical compositions for required products, Design of Experiments (DOE) for trials, Process Efficiency for Cost saving and effectiveness, Properties of product enhancement by proper combination of Raw materials. Training to Process operators and staff about plastics process and related operations, Processing of Thermoplastics (Polyolefin) and Barrier films. ( Nylon, EVOH, PVDC)

KEY COMPETENCIES:

SIX-SIGMA BLACK BELT

Expert in 1 to 11 layers plastics film processing

Blown film Extrusion( Barrier /Non Barrier)

Using Mathematical Models in Polymer Chemistry,

SQC,RACI Matrix, KANBAN,DOE

Value stream Mapping, Poka yoke ( Mistake Proofing)

Production and Operation management.

Specialized in Plastics Chemistry, Maths, Production &operations

SAP (MM module), 5-S Technique.

HMP, GMP, ISO, Kaizen,CPK.

TECHNICAL QUALIFICATION:-

Post Graduate Diploma in Plastics Processing and Testing from CENTRAL INSTITUTE OF PLASTICS ENGINEERING AND TECHNOLOGY (CIPET) AHMEDABAD IN 2005-2007.

ACADEMIC QUALIFICATION:-

Executive-Master of Business Administration (MBA) in Production management From Indian School of Management and Studies Mumbai In 2009-2011 In ‘A’ Grade

Bachelor’s Degree In Industrial Chemistry and Mathematics from RTM Nagpur University In 2005

HSC from Nagpur Board in 2002

SSC from Nagpur Board in 2000

CERTIFICATION:-

Lean Six Sigma -Black belt from Anexas Denmark ( with DMAIC projects in scrap reduction and production efficiency)

Lean Six Sigma -Green belt from Anexas Denmark

NCC ‘A’ ‘B’ and ‘C’ Certificates as a senior under officer.

Business Analytics from Illinois University

Managerial Economics and Business Analysis from Illinois University

Project Management certification from the University of Colorado Boulder.

Sales Operations & Management from West Virginia University

COMPUTER KNOW- HOW:-

MS Office (Word, Excel, PowerPoint), Outlook, Internet.

Working on SAP (MM module) at M/s. Essel Propack Ltd.

Worked on Tally

Worked on Focus software

Worked on Oreo for MIS

MINITAB-14 software for Six Sigma project handling.

Technical Skills (Plastics and Downstream)

Plastics Film Extrusions Machines Exposure:-

Windmoller&Holscher Five layer/Three layers Blownfilm extrusion from Germany- Having and 450kgd/hr and 350 kg/hr output with IBC, Autoguage control, Thickness from 20 mic to 250mic.

MACRO Engineering Seven layer extrusion machine from Canada-Having 550kg/hr output With IBC, Autoguage control, Thickness from 30 mic to 300mic.Film Width 2600mm, Turret Winder, Specialties For PVDC processing Only Machine In Asia.

ReinfenhauserNine Layer(1800) and Three Layer Blownfilm extrusion from Germany- Having 600 Kg/Hr Output with IBC, Film Width 2300 mm., Autoguage Control, Thickness of film 40mic to 300mic.

Printing Machines Exposure

Pelican Flexo Printing (8 colors), Hemingston (6 Colours), WnHMiraflex CI 8 colors

Raw Materials Processed:- Nylon, HDPE,LLDPE, LDPE,mLLDPE, EVA, CoAdhesives, EVOH, PVDC, MDPE, Adhesive polymers, EVA, PVB, (ACP films)All kinds of CI Flexo Inks, Solvents, Varnish

Plastics Film Processed: - Milk film, Oil film, Shrink Film, Hood film, ACP films ( EVA and PVB) Greenhouse film, Silage film, Lamination film, Film for liners, general purpose film, PVDC film, Nycen film, Nytofilm., MulchFilm.All types of Mono layer/three-layer/five-layer/Seven layer/Nine layers blown film. POF 11 Layer Shrink film

Communication Skills

Can Speak and write fluently with good proficiency in English, Spanish, Hindi, Marathi, Gujarati, and Arabic (basic)

Key responsibilities Include:

Collaborate with plant engineering on capital projects (CAPEX) as needed for equipment additions, and component replacement for Plant processing equipment. Scope includes engineering, procurement, construction coordination, job site safety, and project management protocol, to ensure an on-time, on-budget, and safe conclusion as well as the commissioning and start-up of projects. Provide support and expertise to the Project Head to mitigate and/or communicate Safety and Environmental issues associated with the Project.

In Day to day practice using PPAP, DOE, Six Sigma Tools, SQC, RACI, Value stream Mapping, and KANBAN, for the betterment of the process.

Breakdowns in processing machines repair, timely servicing, scheduling preventive maintenance

Coordinate and support the company’s process and material formulation research and development activities by planning, devising, carrying out and analyzing new polymer, raw material, resin and additive formulation/product development experiments toward product performance/cost improvements by company objectives.

Initiate continuous improvement projects in the production area. Use information gathered through, SOCs, QOCs, best practices, trade sources, and Team member inputs. Assist in Department KPI generation and goals with Plant Manager and peers.

As a Plastics Packaging / Extrusion Process engineer, I am handling Blown film extrusion, and new formulation of materials by implementing proper chemical composition and ratio setups for the strength of the films and downstream processes.

Stay abreast of the changes in processing technology. Settle impacts to operations with proposed marketing and sales requests.

Provide specialized advice with analysis of issues such as process breaks, Scrap, Cost, Energy saving, Output optimization, RM combination, and layers formulation concerning customers’ requirements.

Complex processing and operations issues solving for which using my education in specialized area such as Chemistry, Plastics processing and management.

Providing technical and customer requirement coaching programs to the team for their skill enhancement and to understand the importance of customer and there requirements in current scenario Introducing new techniques and developments in processes to fulfill current demands of customers by delivering fast and quality outputs, and also to maintain brand status in market.

Dimension analysis and mass balancing. Individual possesses Technical knowledge of process piping, temperature, Pressure, thermodynamic, fluid behavior, mechanical transmission, I/O PLC controls, production line flow and design. Processing machines drawing.

HSSE compliance tasks assigned to the team and responsible for completing assigned HSSE Compliance tasks effectively and for reporting any potential or actual non-compliance issues

WORK EXPERIENCE:-

Essel Propack Ltd.

Vasind-Thane – Maharashtra( India)

Plastics Extrusion Technician

Feb 2007 to Jul 2009

Responsibilities

oDay to Day-to-day plastics processing including by using the Extrusion Process which mostly emphasizes in high-quality stretch, shrink, custom additives, and converter-grade films used for industrial packaging and agricultural applications.

oWas handling three-layer and Monolayer Blown film machines by following SOPs and SPPs..

oConduct R&D trials according to customer requirements.

oNew recipe development for films, as well as corrections in the formulation of materials with Chemical investigations.

oProcess Optimization (Worked on various projects such as Scrap reduction product change and Process breaks)

oPreventive and Breakdown maintenance.

oTraining to new operators and scheduling their shifts.

oMaintaining machines for proper production and troubleshooting problems during processing of plastics films.

oWorked with HSSE compliance tasks assigned to the team and responsible for completing assigned HSSE Compliance tasks effectively and for reporting any potential or actual non-compliance issues

Poly Product GH Ltd

Accra Ghana (West Africa)

Dec 2009 to March 2013

Asst. Factory manager (Plastics Technologist)

Plastics Blown Film Extrusion, and Print process)

Responsibilities:

oCoordinate and support the company’s process and material formulation research and development activities by planning, devising, carrying out and analyzing new polymer, raw material, resin, and additive formulation/product development experiments toward product performance/cost improvements by company objectives. Initiate continuous improvement projects in the production area.

oUse information gathered through, SOC’s, QOC’s, best practices, trade sources, and Team member inputs. Assist in Department KPI generation and goals with Plant Manager and peers. Handled Blown film machines, Printing( Flexo –CI & Stack) and Bag making departments. Gave training in the plastics blown film department to operators.

oProduction Planning for Blown film and printing department for daily and Weekly basis. Suggesting new plastic material formulations for flexible packaging applications. Recipes or Formulations for films according to application requirements.

oProduction Target setting according to management requirements. Scheduling Preventive maintenance for all three departments with the team. Conduct new trials for films for bags, Printing designs, and Bag making, according to new applications demands.

oHandled complete plants in the absence of the Plant's head.

Al Jabri Plastics Factory

Dubai (UAE)

(Acquired Technovaa)

June 2013 to May 2017

Production Manager (Technical Head)

Plastics Blown Film Extrusion, Printing and bag making)

Responsibilities:

oIn Day-to-day practice using PPAP(Production part approval process), DOE, Six Sigma Tools, SQC, RACI (responsible, accounted, consulted, informed Matrix) Value stream Mapping, and KANBAN, for the betterment of the process. Breakdowns in processing machines repair, timely servicing, scheduling preventive maintenance.

oCoordinate and support the company’s process and material formulation research and development activities by planning, devising, carrying out, and analyzing new polymer, raw material, resin and additive formulation/product development experiments toward product performance/cost improvements following company objectives.

oI was handling Blown film extrusion, new formulation of materials by implementing proper chemical composition and ratios setups for the strength of the films and downstream processes. Stay abreast of the changes in processing technology. Settle impacts to operations with proposed marketing and sales requests. Provide specialized advices with analysis of issues such as process breaks, Scrap, Cost, Energy saving, Output optimization, RM combination, layers formulation concerning customers’ requirements. Was Planning and directing the work related to the machines and downside post processes.

oWere involved in the Costing of Products and process, accordingly managing Raw plastic materials concerning quality. Day to day Production controlling and improvement of capacity of machines and resources necessary for processing products.

oI was handling Blown film extrusion, New formulation of materials by implementing proper chemical composition, Ratios setups for strength of the films and bags.

oWas doing Sealing, Tackiness, tensile, COF testings and giving training to QC guys.

oBrought set up Blown film three layers new lines from Europe and CI and Stack flexo printer from from Europe.

oNew laminates developed for local flexible packaging market. On New Duplex lamination machines from Nordmecchnica.

oNew Material Formulation for local market requirements for Bags, Laminated Pouches, Surface protection ACP films and agriculture.

Sigma Plast Group- Tinflex

Quito . Pichincha. Ecuador

Plastics Extrusion Process Specialist cum Tech. Manager

June 2017 to Sept 2019 Studies of Plant economics also (self-studies)

Responsibilities:

oProcessing of Low-density Polyethylene film, Linear Low-density polyethylene film, Metallocene, Ethylene-vinyl acetate-based Milk film, Oil film, Shrink Film, Hood film, ACP films ( EVA and PVB) Greenhouse film, Silage film, Lamination film, Film for liners, general purpose film, PVDC film, Nycen film, Nytofilm., MulchFilm.All types of mono-layer/three-layer/five-layer/Seven-layer/Nine-layer blown film. POF 11 Layer Shrink film

oResponsible for overall performance of Plastics Blown Film Extrusion and Bag making. Department, regarding productivity, quality, non-conformity & customer complaints.

oSuggest new formulations according to customers’ requirements for commodities as well as special kinds. Such as ACP films (EVA and PVB)

oProviding technical and customer requirement coaching programs to the team for their skill enhancement and to understand the importance of customer and their requirements in the current scenario Introducing new techniques and developments in processes to fulfill the current demands of customers by delivering fast and quality outputs, and also to maintain brand status in market.

o friendly environment within the team and department, also keeping high moral of team by giving appreciation and care.

oOperations of Blown Films Extrusions the subordinates and give training to newcomers. Enhancement of skills of company workers is top priority for my department.

oStays connected with cutting-edge technology/techniques, makes recommendations to the next level and is responsible for implementation.

Norflex Inc.

720 Norflex Dr, Hudson, WI 54016 USA

Sr.Process Engineer

Blown and Cast Extrusion

October 2021 to Continue…

Responsibilities:

Process Specialized activities: Polymers derivatives analysis for Plastics Film Processing, LDPE, HDPE, m-LLDPE, Polypropylene, PPA, Color agents, Adhesives, Tackifiers and master Batches formulations according to Chemical compositions for required products, Design of Experiments (DOE) for trials, Process Efficiency and optimizations for Cost saving and effectiveness, Enhancement of Properties of product enhancement by proper combination of Raw materials. Finished product Testing for Reverse Engineering, Product Dimensions, and design proposals according to customer requirements, PPAP, Six Sigma Tools, SQC, RACI, Value stream Mapping, and KANBAN, for betterment of the process. Training of Process engineers, Maintenance team, and Technicians on process piping, temperature, Pressure, thermodynamics, fluid behavior, mechanical transmission, I/O PLC controls, production line flow, and design. Processing machines drawing. Preparation of SOP (Standard Operating Procedure) for conversion processes. Extrusion Streamlining, SPP suggestions to Processing equipment. Data analysis and improvement in Process and QA. Resolve the technical implementation issues in technologies and deployment issues in production.

Analysis, Design, Maintenance, Performance Tuning for Plastics Processing: Create design documents for defining processes, Quality and Information analyzer jobs, and Analysis and study of existing systems. Identify low-performance SPPs and redesign to improve performance—documentation of test/trial cases and workflow instructions, Customer complaints analysis, etc.

Process Planning and Management:

Identify the scope of projects and deliveries of the proposed system according to appropriate and accurate specifications.

Analysis and Enhancements:

Analysis and study of existing systems. Documentation of business requirements for enhancing application features. Identify new advanced implementation technologies to improve the system performance and do the performance test by creating performance test cases.

Implement the integrated workflows for the relevant modules.

Personal details:

Full name Shrikant Bhaskar Kale

Father’s name: Bhaskar Savaji kale

Date of Birth: 27/09/1984

Gender: Male

Marital status: Married

Nationality: Indian

Visa Status: H1B (Authorized to work in the USA)

Languages Known: English, Spanish, Hindi, Marathi and Gujrati

Driving License: USA, UAE, India and Ghana

Hobbies: Reading, Swimming, and Traveling.

Declaration

I hereby declare that the above information furnished by me is true and up to date.

[Shrikant Bhaskar kale]

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