AJAY KUMAR
Lucknow
Summary
Quality-focused engineer with over 11 years in 3-piece can manufacturing, tin printing, and metal packaging across multiple countries. Led quality operations, managing comprehensive quality control from materials to shipment. Certified ISO 9001:2015 and FSSC 22000 V6 lead auditor with expertise in BRCGS packaging, CAPA, and root cause analysis. Delivered significant improvements in audit performance and reduced rejection rates.
Overview
4
4
Languages
1
1
Certification
11
11
years of professional experience
Work History
Quality Head – Tin Printing, Coating & 3-Piece Can Mfg.
Golden Era Printing & Packaging | Gayatri Cans (Pty) Ltd.
Johannesburg
06.2025 - Current
Quality Head – Tin Printing, Coating & 3-Piece Can Manufacturing
Golden Era Printing & Packaging | Gayatri Cans (Pty) Ltd.
Johannesburg
06.2025 - Current
- Lead the full quality function across 3-piece can manufacturing, tin printing, and coating — governing standards from incoming raw material through to final shipment for food-grade , and industrial product lines.
- Manage seam integrity checks, print registration verification, coating adhesion testing, and can-body dimensional conformance to ensure 100% specification compliance before dispatch.
- Drive BRCGS A+ Grade audit readiness through structured internal audits, CAPA management, NCR resolution, and cross-departmental corrective action ownership.
- Direct root cause investigations (Fishbone, 5-Why, 5M) for customer complaints and in-process non-conformances, issuing formal CAPA reports and verifying corrective outcome closure.
- Led daily Gemba walks to identify live quality risks, coached operators on first-time-right standards, fostering a proactive quality culture across all production shifts.
- Developed and presented KPI dashboards and quality trend analysis to plant leadership, utilising SPC and Pareto Analysis for targeted defect reduction and scrap minimisation.
- Coordinated with material suppliers to resolve incoming quality issues in tinplate, inks, lacquers, minimising line stoppages from material non-conformance.
- Train and develop the QA team on inspection methods, food safety protocols, calibration management, and audit documentation — continuously improving team competency and audit readiness.
QA / QC Supervisor – Printing Department
Saudi Arabian Packaging Industry W.L.L (SAPIN)
Ad Dammam
12.2023 - 05.2025
QA / QC Supervisor – Printing Department
Saudi Arabian Packaging Industry W.L.L (SAPIN)
Dammam
12.2023 - 05.2025
- Supervised quality on KBA 6-Colour + Coating Unit and Fuji-3 + Coating Unit lines for Nestlé, Al Marai, Anchor, Jotun, KPC, Hempel, and Arla Food across food, paint, chemical, and aerosol cans.
- Played a key role in supporting ISO 9001 2015 and FSSC 22000 V5.1 QMS documentation and compliance across the printing department, leading to successful external certification audits.
- Developed KPI reporting framework for rejection rate, scrap %, and customer complaint frequency, facilitating data-driven defect reduction and measurable process improvements.
- Utilised PDCA, Pareto analysis, and SPC to identify key defect causes and implement permanent CAPAs, confirmed through ongoing process monitoring.
- Managed calibration and traceability records for all inspection gauges; standardised QC forms, control plans, and procedures to improve inspection consistency across shifts.
- Coached and evaluated quality team members through structured development programs, enhancing team capability and improving departmental audit outcomes.
Printing Production Supervisor
Muscat Cans Co. LLC / Oman Foodstuff Factory LLC
Muscat
11.2022 - 10.2023
Printing Production Supervisor
Muscat Cans Co. LLC / Oman Foodstuff Factory LLC
Muscat
11.2022 - 10.2023
- Supervised full-shift production on KBA Metal Star 2 printing line in an ISO 22000:2018-certified facility, meeting daily output, quality, and food safety targets for Nestlé, Al Mudhish, Anchor, and Arla Food.
- Planned production scheduling, monitored workflow continuity, and proactively resolved bottlenecks, ensuring zero food safety non-conformances during production cycles.
- Led multi-operator shift team; established performance expectations for output, quality, and safety compliance while conducting regular performance reviews.
- Maintained accurate shift-level production and quality records, equipping management with reliable data for planning reviews and customer reporting.
Assistant Manager – Printing Department
Metal Cans Co. Ltd.
Sonipat, Haryana
10.2016 - 10.2022
Assistant Manager – Printing Department
Metal Cans Co. Ltd.
Sonipat, Haryana
10.2016 - 10.2022
- Managed quality and production on Crabtree Marquess Double/Single Color and Yodogawa printing lines for AkzoNobel, Berger, Asian Paints, Pidilite, and Nippon Paints across 100 ml – 5-litre printed tins and OTS 3-piece cans.
- Led sample development, shade matching, ink mixing, artwork verification, reducing colour deviation complaints and shortening customer approval cycle times.
- Identified root causes of defects using Fishbone and 5-Why analysis; maintained NCR logs and implemented CAPAs, eliminating repeat non-conformances.
- Trained junior quality and production personnel on inspection methods, equipment operation, and SOP adherence — reducing error rates and improving first-pass quality output.
- Executed ETP tinplate testing for tin coating weight, temper grade, dry film weight, lacquer adhesion; managed documentation and product traceability from printing to shipment.
- Promoted from Quality Control Engineer to Assistant Manager within two years — recognised for quality leadership and expanding operational contribution across a 6-year tenure.
Quality Control Engineer
Sagar Ispat India Pvt. Ltd.
Baddi, Himachal Pradesh
01.2016 - 09.2016
Quality Control Engineer – Printing Department
Sagar Ispat India Pvt. Ltd.
Baddi, Himachal Pradesh
01.2016 - 09.2016
- Conducted in-process quality inspections and lab tests — film weight measurement, shade panel preparation, ink mixing, shade matching — for printed tin containers and drums (100 ml – 30 L) supplied to AkzoNobel, Berger, Asian Paints, Pidilite, and pharmaceutical clients, ensuring adherence to quality standards.
- Completed B. Tech industrial training and retained position post-qualification, demonstrating technical readiness and commitment to quality assurance from the start of my career.
- Tested equipment, machinery and instruments to assess proper functioning.
- Checked and recorded incoming raw materials, verified quality against established specifications and updated inventory systems with new quantities.
- Negotiated with vendors to improve component quality, resulting in enhanced final product reliability.
Education
B. Tech - Mechanical Engineering
Maharishi Markandeshwar (Deemed) University
Haryana01-2016
Intermediate - Mathematics & Science
D.A.V. Degree College
Lucknow, U.P.01-2012
Skills
- Quality Management
- BRCGS Compliance
- ISO compliance
- Food Safety Systems
- CAPA & NCR Management
- Root Cause Analysis
- Fishbone Analysis
- Lean Manufacturing
- Continuous Improvement
- Process optimisation
- Operational Excellence
- Audit Management
- Statistical Process Control
- Statistical quality control
- Control Plans
- Process Audits
- Risk Management
- Risk Assessment
- Validation processes
- Corrective Actions
- Preventive Actions
- Gemba Walks
- 5S Kaizen Lean Manufacturing
- Kaizen
- 5S Implementation
- FMEA
- 5M Analysis
- Pareto Analysis
- Production Management
- Team Leadership
- Customer Complaint Management
- Supplier Quality
- AQL Management
- Quality reporting
- Quality management tools
- Quality & Manufacturing Systems
- Manufacturing Excellence
- KBA 6-Colour Coating Unit
- 3-Piece Can & Metal Packaging Lines
- ERP software
- MS Office (Word, Excel, PowerPoint)
- CAD software
- Autodesk 3ds Max Photoshop
- CorelDRAW
- ISO 9001:2015 FSSC 22000 V51/V6
- ISO 22000:2018 BRCGS Issue 7
- Six Sigma White Belt
- Audit management
- Validation processes
- Corrective Actions
- Preventive Actions
LANGUAGES
English (Professional)
Hindi (Native)
Punjabi, Bhojpuri
Assamese (Conversational)
Certification
- Professional Certifications
- Mechanical Engineering (2012 - 2016)
- ISO 9001:2015 QMS & FSSC 22000 V6 — Certified Lead Auditor
- BRCGS Global Standard for Packaging Materials Issue 7 — Sites Training (For Gayatri Cans PTY Ltd.)
- ISO 9001:2015 — Quality Management System (QMS) Certified
- ISO 22000:2018 — Food Safety Management System (FSMS) Certified
- Hazard Analysis and Risk Assessment (HARA) — Certified
- Six Sigma White Belt — Production & Quality (Aveta Business Institute, 2022)
Accomplishments
- Successfully achieved A+ Grade in BRCGS Audit through strong quality system implementation, compliance management, audit preparedness, and cross-functional team engagement.
- Supported full ISO FSSC 22000 V5.1 QMS implementation at SAPIN within operational timelines, contributing to successful external certification and establishing a departmental compliance benchmark.
- Eliminated customer complaint recurrence for Nestlé, Arla Food, Al Marai, and Jotun through structured root cause analysis and evidence-based CAPA closure.
- Built KPI and scrap trend reporting framework at SAPIN, enabling targeted rejection reduction and measurable waste savings across printing production runs.
- Progressed from QC Engineer to Assistant Manager at Metal Cans Co. within two years, recognised for consistent quality outcomes and growing cross-functional leadership.
- Maintained zero food safety non-conformances across all food-grade metal packaging accounts at Muscat Cans throughout the entire ISO 22000:2018 production cycle.
- Built and led quality teams across four countries — India, Oman, Saudi Arabia, South Africa — adapting to diverse regulatory frameworks and multinational customer requirements.
Websites, Portfolios, Profiles
linkedin.com/in/er-ajaykumar-834bb4b8
Disclaimer
I hereby declare that all information provided in this Curriculum Vitae is true, complete, and accurate to the best of my knowledge and belief. I understand that any misrepresentation or omission may affect the consideration of my employment. Supporting documents and references will be provided upon request. Place: Johannesburg (South Africa ) Date: 03-May-2026 Ajay Kumar
Timeline
Quality Head – Tin Printing, Coating & 3-Piece Can Mfg.
Golden Era Printing & Packaging | Gayatri Cans (Pty) Ltd.
06.2025 - Current
Quality Head – Tin Printing, Coating & 3-Piece Can Manufacturing
Golden Era Printing & Packaging | Gayatri Cans (Pty) Ltd.
06.2025 - Current
QA / QC Supervisor – Printing Department
Saudi Arabian Packaging Industry W.L.L (SAPIN)
12.2023 - 05.2025
QA / QC Supervisor – Printing Department
Saudi Arabian Packaging Industry W.L.L (SAPIN)
12.2023 - 05.2025
Printing Production Supervisor
Muscat Cans Co. LLC / Oman Foodstuff Factory LLC
11.2022 - 10.2023
Printing Production Supervisor
Muscat Cans Co. LLC / Oman Foodstuff Factory LLC
11.2022 - 10.2023
Assistant Manager – Printing Department
Metal Cans Co. Ltd.
10.2016 - 10.2022
Assistant Manager – Printing Department
Metal Cans Co. Ltd.
10.2016 - 10.2022
Quality Control Engineer
Sagar Ispat India Pvt. Ltd.
01.2016 - 09.2016
Quality Control Engineer – Printing Department
Sagar Ispat India Pvt. Ltd.
01.2016 - 09.2016
B. Tech - Mechanical Engineering
Maharishi Markandeshwar (Deemed) University
Intermediate - Mathematics & Science
D.A.V. Degree College