Production Manager in Plaster Board Industry

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Serial No: 14219

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Current location:  Al Madinah Province, Saudi Arabia - View on map

Nationality: Indian

Spoken languages: Arabic, english, Hindi, KANNADA, Tamil

Qualifications/Training

2013 International MBA in Operational Management from United Business Institute, Belgium with 66.7%

2004 B.E. in Chemical Engineering from St. Michael College of Engineering & Technology, Madurai with 74.3%

• Gypsum Board Manufacturing Technology Training by Mr. Peter Childs from India Gypsum Ltd., WADA, Maharastra

• AM (Autonomous Maintenance) Practitioner Training Course by Mr. Derek Tyeson from Saint Gobain Gyproc Ltd.

Profile Summary

A result-oriented professional with over 10 years of experience in:
Production Operations Quality Control Cost Management
Manpower Planning Team Management Material Management
Resource Management Process Enhancement Liaison & Coordination

• Presently associated with Alwatania Gypsum Company Ltd., Yanbu, KSA as Production Manager
• Result-oriented visionary executive with expertise in Production Operations with complete accountability of formulating & implementing business plans and driving operational excellence
• Experience in planning all the production activities as per the capacity & availability of resources with skills in identifying areas of improvement and recommending process modifications to enhance operational efficiencies
• Proficient in managing entire production operations involving resource management, materials planning & co-ordination with internal departments
• Expertise in ensuring compliance with various quality measures by maintenance of appropriate requisite documentation/records
• Deft in handling the QA operations, optimizing resource utilization and enhancing productivity & operational efficiencies
• An effective communicator with excellent analytical, problem solving and interpersonal skills

Core Competencies
• Formulating & executing the production and manpower schedules / plans for smooth execution of projects within time & cost parameters
• Coordinating with various departments including material department for ensuring accomplishment of daily & monthly production targets; ensuring cost reduction by implementing new techniques and working on productivity improvement
• Implementing quality tools to ensure process capability as per specification requirements, monitoring by preparing control plan improvement & corrective action plan
• Developing quality plans and ensuring quality control for equipment in manufacturing by inspection control in various stages & process control as per standard
• Formulating operational policies and implementing process improvements to ensure superior quality & outstanding output of employees
• Creating plans & processes which minimize costs through effective utilization of manpower, equipment, facilities, materials & capital

Organizational Experience

Since Aug’13 Alwatania Gypsum Company Ltd., Yanbu, KSA as Production Manager
Role:
• Managing & leading a team of over 50 members including Plaster & Board Plant and Quality Section
• Handling production planning with the sales & marketing department and controlling the available resources
• Coordinating with the supplier regarding purchase any new machine starts from technical discussion, quotation and releasing the purchase order
• Responsible for achieving the production target as per the budget
• Carrying out manpower calculation and monitoring manpower utilization
• Monitoring the quality of product and following up regarding critical materials from the purchase team
• Ensuring the required gypsum supply quantity for production from the gypsum quarry as per the agreement between the company and the contractor
• Preparing & planning the weekly maintenance activity with maintenance manager
• Interfacing technical discussion with the machine supplier if any quality issues rises thereby solving the problems

Highlights:
• Received special thanks from CEO for large contribution in commissioning & process engineering which led to increase in turnover/year by 18 million SAR and delivering good products to the customer
• Earlier 89 gms/m2 starch was used for manufacturing; suggested 69 gms/m2 starch which led to reeducation in starch consumption on average of 400 kgs/day & manufacturing cost by 0.04 SAR/m2 which led to increase in profit by 0.27 million SAR/Year- Received verbal appreciation was given by General Manager/Plant Manager
• Earlier 33 tons of stucco was going wasted; suggested the idea of material to be produced along with the product which led to profit increased by 0.06 million SAR/Year also reduced the plaster consumption in boardplant on average of 33 tons/month
• Earlier 2.7 tons of paper was going as waste; suggested the idea of material to be produced along with the product which led to increased in profit by 0.08 million SAR/Year also received verbal appreciation by General Manager/Plant Manager
• Earlier there was less production in the plant; suggested increase in production which led to increased in profit by 0.7 million SAR/Year

Feb’11 to Jul’13 Micro pack Ltd., Bangalore as Executive Manager –Production
Role:
• Led a team of over 40 members including Electro & Electroless Plating, De-Smear Process, Outer Layer Photo Printing, Deburring, Quality Lab and plasma Line
• Accountable for streamlining the production flow through process mapping & value stream mapping thereby reducing the waste, increased the productivity and improving the yield
• Carried out Root Cause Analysis for the customer complaints and CAPA implementation
• Conducted manpower calculation and monitored manpower utilization stations
• Provided training to all the operators in various skills and improved skill matrix resulting in reduced overtime
• Responsible for providing direction, training & motivating t the team for ensuring optimum performance
Highlights:
• Initially on an average 5 saddles were replaced in a week due to breakage; suggested replacement of Ceramic Fibre Saddles to Poly Propylene Saddles which led to decrease in spare parts cost by 0.08 million INR/Year
• Earlier the products received scratches due to fewer gaps between the panels; suggested number of combs in the jigs to be reduced thereby eliminated human error which led to decrease in rejection percentage by 1.25%
• Initially De-Smear process was handled manually; initiated safety environment to be created after line was commissioned this led to On Time Delivery and reduction in product cycle time by 1.5 hrs; received verbal appreciation by Executive Director/President

Feb’08 to Jan’11 Saint-Gobain Gyproc India Ltd., Bangalore as Senior-Production Engineer
Role:
• Handled process control & troubleshooting through Siemens PLC-SCADA Programming System and IMS-Integrated Management System (ISO 14001 & OHSAS 18001)
• Generated production output confirmation through online MOVEX software to Head Office
• Prepared daily, weekly & monthly reports
• Oversaw inventory control of raw materials
• Analyzed the plant stoppages to suggest remedial measures to avoid the reoccurrences
• Formulated & implemented work SOP to improve understanding of jobs and performing them in most effective way
• Responsible for following up with the Safety Permit to carry out any maintenance job and ensured safe work in the field
• Served as 5S leader for the particular zone of production department
Highlights:
• Earlier average yield was 96%; led to overall yield increase up to 97% which led to increase 1684 m2 of production
• Earlier received on an average 1 complaint in a week for sagging defect; suggested to lead customer complaint sagging to zero leading to improved quality of the product- received verbal appreciation by General Manager/Production Manager

PREVIOUS EXPERIENCE

May’04 to Jan’08 Bhuruka Gases Pvt. Ltd., Bangalore as Production Executive