Ajay Shivaji Nikam
Rewari
Summary
Results-driven Process Lead with over 13+ years of experience in pharma manufacturing, specializing in raw materials preparation, process optimization, and compliance. Expertise in lean manufacturing, Six Sigma methodologies, and GMP regulations. Proven ability to lead high-performing teams, improve efficiency, and ensure regulatory compliance. Seeking to leverage my skills to enhance production processes and maximize operational excellence.
Overview
14
14
years of professional experience
1
1
Certification
Work History
Process Team Lead - Operations
Lonza (Capsugel Healthcare Pvt. Ltd.)
Rewari
01.2024 - Current
- Managed and led the team at a unionized plant, responsible for production, process, and quality of the product, focusing on strategic planning.
- Lead a team of 20+ employees in raw material preparation, ensuring accurate weighing, and compliance with GMP and quality standards.
- Working on a quality improvement program (QIP) utilizing lean six sigma methodologies to drive process enhancements, reduce defects, and improve overall product quality.
- Ensure accountability for achieving and delivering objectives aligned with business targets, encompassing productivity, machine uptime, cost reduction, and machine effectiveness.
- Responsible for day-to-day production reporting via management information system.
- Driving continuous improvement and lean projects using project management skills and innovative programs.
- Develop and implement capacity planning & scheduling strategies to ensure timely material preparation for production.
- Conducting and performing a training program for departmental employees to improve the skills of employees.
- Conduct internal controls and audits, ensuring adherence to legal regulations and internal SOPs.
- Execution, coordination, review, and closure of batch documents.
- Drive process optimization initiatives utilizing Lean Six Sigma methodologies, reducing defects and improving efficiency.
- Managing the entire manufacturing operations, including resolving the problems and addressing them periodically with the appropriate actions.
- Review and lead the planning and manpower allocation.
- Coordination with Q.A., Packing, Quality Control (IPQC and Micro), Engineering, and Utilities Department for production activity.
- Conducting regular operational indicators (KPIs) and implementing corrective actions to achieve performance targets.
- Collaborate with department heads to align operational goals with overall business objectives.
- Ensure the delivery of a high-quality product by implementing and monitoring the quality assurance process.
- Develop and maintain Standard Operating Procedures and work instructions for the entire production process, and monitor if the subordinates are complying with them to reduce failures.
- Coordinate for production line maintenance or downtimes to minimize disruptions to manufacturing schedules.
- Participate in regular meetings, shop rounds to ensure compliance with factory rules and standards set for industrial safety, environmental systems to meet quality and business standards.
- Analyzed inventory reports determining root cause of discrepancies.
- Created reports outlining daily, weekly, monthly activities, progress achieved against targets and any issues encountered during the period.
- Notified supervisors about production problems and helped identify and correct concerns.
- Maintain traceability of materials, ensuring detailed record-keeping and compliance with Good Manufacturing Practices (GMP).
- Provide onboarding and training for new employees, ensuring they adhere to standard procedures and quality benchmarks.
Assistant Executive - Process & Raw Materials
ACG Capsules Pvt. Ltd.
Shirwal
05.2014 - 12.2023
- Oversaw the department in shift, reduced wastage, and improved productivity with strategic planning.
- Managed production planning and raw material usage, ensuring process efficiency and minimizing waste.
- Educate and communicate on key production issues with the subordinates, and invite comments, new ideas, and suggestions from them on safety, quality control, maintenance, and productivity.
- Developed and maintained Standard Operating Procedures (SOPs) for raw material handling and quality assurance.
- Collaborated with cross-functional teams to drive strategic improvements, increasing productivity and compliance.
- Led training programs to enhance employee skill sets in quality control, safety, and operational efficiency.
- Monitor the effective responsibility for product quality, which covers incoming inspection of raw material, in-process inspection, and final inspection of the product.
- Oversaw employee progress, safety, and project implementations.
- Performed equipment inspections and kept detailed records.
- Resolved conflicts between team members or other departments regarding project timelines or goals.
Process Technician
Essel Propack Ltd.
Wada
06.2011 - 04.2015
- Operated and maintained printing machinery, ensuring optimum efficiency and minimal downtime.
- Performing shift preventive maintenance (SPM) to prevent major downtime and improve machine consistency and productivity.
- Conducted preventive maintenance to enhance machine productivity and reduce operational failures.
- Performed routine equipment maintenance on nights and weekends to prevent downtime.
- Executed quality inspections on raw materials and final products, ensuring adherence to customer specifications.
Education
Some College (No Degree) - Post Graduate Diploma in Packaging
SIES School of Packaging Technology
Mumbai09-2025
High School Diploma -
Government Institute of Printng Technology
Mumbai05-2011
Skills
- Raw Materials Management & Compliance
- GMP & Regulatory Adherence
- Lean Six Sigma & Process Optimization
- Capacity Planning & Scheduling
- Training & Development
- Cross-Functional Collaboration
- Inventory & Traceability Management
- Quality Assurance & Internal Audits
- Operational Excellence & OEE Improvement
- Safety & Risk Management
Certification
- Lean Six Sigma Yellow Belt Certified
- Packing Supervisor/ In-Charge – Life Sciences (Skill India Certified)
- Certified Prashikshak (Trainer) – ACG Capsules
Accomplishments
- Best Supervisor of the Quarter – Awarded for exceptional leadership and process improvements at ACG Capsules.
- Kudos 5-Star Award – Recognized for successful implementation of departmental line layout improvements.
- Training Program Recognition – Appreciated by ACG Europe for conducting effective employee training programs.
Languages
- English, proficient.
- Hindi, expert.
- Marathi, native.
Affiliations
As a Process Expert, I traveled to ACG Capsules’ overseas plant in Croatia, Europe, to conduct employee training and lead process optimization initiatives within the department.
Strengths
- Process Optimization – Passionate about reducing inefficiencies and driving productivity improvements.
- Team Leadership – Adept at building collaborative environments and ensuring high employee engagement.
- Problem Solving – Quick at identifying and resolving process bottlenecks for continuous operational improvements.
Software & Tools
- SAP ERP
- Microsoft Office Suite (Excel, Word, PowerPoint)
- Manufacturing Execution Systems (MES)
Timeline
Process Team Lead - Operations
Lonza (Capsugel Healthcare Pvt. Ltd.)
01.2024 - Current
Assistant Executive - Process & Raw Materials
ACG Capsules Pvt. Ltd.
05.2014 - 12.2023
Process Technician
Essel Propack Ltd.
06.2011 - 04.2015
Some College (No Degree) - Post Graduate Diploma in Packaging
SIES School of Packaging Technology
High School Diploma -
Government Institute of Printng Technology
Similar Profiles
Preeti KapasiPreeti Kapasi
Marketing Automation Manager at LonzaMarketing Automation Manager at Lonza
Sarah LynchSarah Lynch
CQV Engineer at LonzaCQV Engineer at Lonza
MOHAMMED ALKHAWAJAHMOHAMMED ALKHAWAJAH
Quality Assurance Validation Engineer at LonzaQuality Assurance Validation Engineer at Lonza