Alliston Fernandes

Production:
• Planned Production Schedules and monitored them on regular basis ensuring products dispatched as per committed timelines thorough managing a staff of 15+.
• Controlled costs and optimized spending via restructuring of budgets for labor, capital assets, inventory purchasing, External Agency expenses(Service providers & AMC) and technology upgrades.
• Set annual targets for wastage reduction and efficiency improvements and monitored and complied on the same.

• Adjusted job assignments and schedules to keep pace with dynamic business needs, factoring in processes, employee knowledge and customer demands.
• Coordinated with customer care team and internally brainstormed solutions to help reduce customer complaints. Incase of major investment like new machinery, process study was carried out and same was presented to the management.
  • Provided Monthly MIS reporting with Targets / Status and action plans for Process improvement, Throughput yield, Machine utilization and Manpower utilization.
  • Handled plant related compliances, liaising with IDC, Electricity Dept, Pollution Control board, Fire safety, Legal metrology etc.
  • Handled factory inspections and audits of FSSAI, HALAL, FSSC certified (TUV Nord) and 3rd party MNC's.
  • Effectively trained team on the process systems, machines, safety and 5s and also trained them to manage their own respective stations creating a systematic distribution of work.
  •Cross-trained existing employees to maximize team agility and performance.
• Resolved staff member conflicts, actively listening to concerns and finding appropriate middle ground.
• Created a department appreciation program where ones ideas/achievements were appreciated.

Maintenance:
• Trained Maintenance Team and Designed effective maintenance schedules and procedures to reduce repetitive stoppages by modifying existing practices, hence avoiding major breakdowns.
• Monitoring and controlling maintenance costs by finding suitable replacements for parts, carrying out predetective maintenance, having the right tools for the right job, internally managing tasks which would normally be assigned to external agencies.
• Reduced major down time in production by stocking critical spares.
• Trained my team do a proper service routine of all external process tasks like Calibrations, AMC scheduling, Facility maintenance, A/C servicing, Gas bank maintenance.
• Oversaw maintenance activities done and then educated team to perform better.
• Executed Machine commissioning in plant and making sure all utilities were available and proper handover and training was given by the OEM team.
• Created Whatsaap groups with OEM so that minor/major issues would easily be resolved with their help to achieve better OEE.

Highlights:

• Used six sigma and reduced the defective product quantities below 3% in one year.
• Implemented in-house process redesigns and automations to reduce process bottlenecks and increase productivity while reducing operational costs.
• Successfully implemented certification of FSSC 22000 which is a global ISO safety standard.
• Was part of the core ERP team to implement online documentation which helped streamlining of jobs and provided transparent product traceability.

• Leading and assisting in set up electrical section of assembly lines for new products.
• Managing daily technical output of 40+ staff, providing feedback to align output with projects / goals ensuring team is in line with production schedules.
• Electrical trouble shooting of machines during testing and trying to reduce downtime through fish bone analysis.
• Incorporated mentoring and prioritized tasks to manage staff performance and development.
• Cost reduction on machines by localization of parts.
• Reduced production costs by optimizing processing methods, re engineering of machine parts, streamlining procedures, making time efficient jigs through Kaizen.

Highlights:

• Awarded Putzmeister Star Employee of Quarter IV 2018 for major cost savings achieved in Electrical assembly for Year 2018.
• Awarded Putzmeister Star Team of Quarter IV 2019 for successful execution in launching of new model in Batching Plant in limited time frame.

• Executed and assisted in planned preventive maintenance for plant equipment. Undertook activities of pre-detective maintenance, identifying repetitive breakdowns and resolving same through analysis.
• Assisted in up keeping building facility on day today basis and listing observations on shop floor.
• Handled breakdown maintenance of machines like Tablet Compression Machines, Coating Machines, Blister Packing Machines, Carton Pack machines, and Bottle pack line Machines with focus on reducing downtime.
• Monitored plant machine to reduce operation cost by re-engineering/ overhauling of existing machine for enhancement.
• Assisted in conducting technical training to Engineering staff.
• Ensuring job allocation to team on daily routine.
• Maintaining spares inventory of critical equipment and cost cutting by finding suitable replacements for spares and cost effective vendor development.

Highlights:

• On spot appreciation award ‘ABHINANDAN' received for identification and rectification of major near miss incident of Tipping machine which would have otherwise led to fatal accident.
• Led and assisted plant projects like Servo collation of Blister line machine by integrating Blister pack machine and carton pack machine which were previously run independently.
• Assisted in installation of Encoder based Camera Inspection systems on bottle pack lines working within tight deadlines and fast-paced atmosphere.

• Supervised, coordinated daily maintenance activities within department and managing 10+ staff of technicians
• Handled break down maintenance of Continues Compression Molding machines, Slitting and Rotary cap printing machines with focus on reducing downtime.
• Participated in continuous improvement by generating suggestions, engaging in problem-solving activities to support teamwork.
• Assisted maintenance activities of utility equipment such as Diesel Generator sets, Screw Compressors, Chillers, lifts.
• Maintained spares of critical equipment and reduced costs by finding suitable replacements for spares.

Highlights:

• Confirmed to Engineer position within 6 months of my training period due to dedication, hard work and performance.
• Modified raw material feed silo systems from manual to automatic to reduce man handling and time losses.
• Assisted Plant projects like Installation of centralized UPS system to separately power machine control systems to reduce loss of starting time after power failures and software malfunction.