ALOK KUMAR RAO
Thane
Summary
Dynamic and results-oriented professional with 12+ years of extensive experience in driving Operational Excellence through TPM methodologies. Adept at leading cross-functional teams, fostering Gemba-focused environments, and implementing strategic continuous improvement initiatives. Skilled in developing training programs, facilitating Kaizen, 5S events, and Lean problem-solving tools . Proven expertise in project management, Operational efficiency, and Business continuity. Certified certified by Saint-Gobain and Internal IMS auditor, with a consistent track record of achieving manufacturing cost reduction through measurable Quality and Productivity . Successfully 2 Plant Setup (1-ALLY Gold Pvt ltd , Sparkling chain Pvt ltd.)
Overview
1
1
Language
12
12
years of professional experience
Work History
Production Manager
Royal Chain Ltd
07.2025 - Current
- Should have Knowledge of Gold purity, Melting and Loss control.
- Enhance Product and Process Quality by reducing defects, increasing First Time Right (FTR), and deploying standard work practices and visual management
- Developed and implemented strategies to eliminate operational waste and enhance product quality using LEAN principles.
- Boosted productivity by 81% through the implementation of a two-die concept using Lean tools, contributing 38% to the plant's overall performance
- Analyzed operations and proposed cost-effective process improvements using ECRS methodology (eliminate, combine, rearrange, simplify.
- Designed and implemented an effective daily management system with relevant KPIs to maintain quality standards at all organizational levels
- Improve Productivity and Reduce Operational Costs by identifying inefficiencies, implementing cost-saving initiatives, and optimizing resource utilization
- Responsibility for Tarpatta Machine/ Flattting, wire Drawing machine.
- Responsibility for Machine chain like Box chain, Anchor chain, Left & Right Curb chain.
- Laser Cutting, Laser Welding.
- Lead and Manage Strategic Projects from planning to execution, ensuring timely delivery, resource alignment, and realization of targeted benefits
- Hollow Rope Chain Departments.
- Monitor and minimize Loss (wastage) and recovery percentages.
- Hollow Handmade Chain all type like Indo chain, Super hollow, Hollow Nabavi chain.
- Italian Choko Chain 22k/20k/18k & Italian Bracelet.
- Responsibility of Katiyar bracelet, South bracelet, Fenchi bracelet, Cuben bracelet
- Polish Department Drum Polish, Magnet Polish & GPC with 95% recovery gold.
- Buffing & Chatka Polish with 95 % recovery .
- Lobster & Stamping Die ,Hollo Pipe cutting room Hemring room Etc.
- Facilitate coordination with other departments for equipment availability and optimization of the resources.
- Preparing and implement a plan for material and spare parts consumption for the annual overall repairs.
- Created maintenance work instruction to assist associates with complex troubleshooting for equipment.
- Knowledge of Scratches, dents or excessive solder/glue all Jewellery Product.
- Missing parts, improper fit of stones or other components checking.
- Poor fit/finish, mismatched colors, misaligned patterns/labels.
- Sharp edges or points, frayed or exposed wires, poorly made repairs.
- Maintain documentation relating to the design and refinement of the program.
- Responsibility chain defect checking, KDM over leaping checking.
- Lead the setup of the Chain manufacturing unit.
- Soldering & shining checking.
Technical & Production Manufacturing Head(Manager)
Sparkling chain Pvt Ltd
03.2024 - 06.2025
- Knowledge of Scratches, dents or excessive solder/glue all Jewellery Product.
- Missing parts, improper fit of stones or other components checking.
- Poor fit/finish, mismatched colors, misaligned patterns/labels.
- Sharp edges or points, frayed or exposed wires, poorly made repairs.
- Maintain documentation relating to the design and refinement of the program.
- Responsibility chain defect checking, KDM over leaping checking.
- Lead the setup of the Chain manufacturing unit.
- Soldering & shining checking.
- Sparkling Chain Pvt Ltd designs, manufactures, assembles, cuts, polishes, markets, and sells gold and silver jewelry in India. The company offers necklaces, rings, pendants, bracelets, earrings, bangles, and various other jewelry, as well as customized jewelry. It also imports, exports, buys, sells, deals, distributes, and wholesales jewelry. The company serves wholesalers, showrooms, and retailers. Sparkling Chain Pvt Ltd was founded in 2023 and is based in Thane, India.
- (Branch of SKY GOLD )
Engineer in Production & Maintenance Department.
A. R . Gold Pvt ltd
06.2017 - 03.2024
- Created maintenance work instruction to assist associates with complex troubleshooting for equipment.
- Successfully introduced the Star Performer Award scheme to enhance plant productivity and employee efficiency through a structured reward and recognition system
- Knowledge of Scratches, dents or excessive solder/glue all Jewellery Product.
- Missing parts, improper fit of stones or other components checking.
- Poor fit/finish, mismatched colors, misaligned patterns/labels.
- Sharp edges or points, frayed or exposed wires, poorly made repairs.
- Maintain documentation relating to the design and refinement of the program.
- Responsibility chain defect checking, KDM over leaping checking.
- Lead the setup of the Chain manufacturing unit.
- Soldering & shining checking.
- Stamping Press Operators set up, operate, or tend machines to inspect, cut, shear, slit, punch, crimp, notch, bend, or straighten Gold material.
- Handling Machine chain Department.
- Line balancing of components at various stages to avoid bottlenecking and excess inventory.
- Handling skilled manpower, administration of shop floor and breakdown slip.
- To ensure quality on line & provide on line for any customer near miss- defect, Material handling.
- Working with SOP
- Knowles 7QC tools ,4M check sheet.
- Setting up machines to start a production cycle ,Controlling and adjusting machine settings.
- Customer complain handling.
- A. R. Gold Private Limited is an unlisted private company incorporated on 08 July, 2004. It is classified as a private limited company and is located at MIDC Industrial Navi Mumbai India Making Gold Jewelry Manufacturer , rings, earrings, necklaces, bracelets, chain, bangle, silver rings. It holding 83.98% market share in Gold manufacturer and having 5 branch in India Mumbai, Delhi , Ahmedabad, Bangalore & Dubai Etc
line leader of Assembly section on Production department
KEIHIN FIE PVT. LIMITED
01.2016 - 06.2017
- Responsibility for carburetor assembles line.
- Preparing daily & monthly production reports.
- To utilize the men, machine & material.
- Manpower deployment as per daily Production Requirement.
- To ensure timely delivery of product to the customer.
- Daily production Plan as par required by PPC .
- Implementation of 5S, KAIZEN & Continues improvement related to cost, Moral, Safety and related processes.
- Monitoring the product/process/manpower/materials problem and initiating corrective action for on schedule Target completion.
- Handling skilled manpower, administration of shop floor and breakdown slip.
- To ensure quality on line & provide on line for any customer near miss- defect, Material handling.
- Working with FSF, OIC, DPR, DRR,SOP,OPL,POKA-YOKE,KAN-BAN, 4M Check Sheet,7QC TOOLS,PP, Breakdown Slip, Production Control Chart, Cycle time monitoring sheet, Skill Matrix, Machine check sheet, etc document.
- KEIHIN FIE PRIVATE LIMITED is a Japanese MNC, situated at Bawal Haryana, India. Making Carburetor and Air suction valve for two wheeler industry. It holding 74% market share in Carburetor manufacturer and having 18 plants in overseas. Major customers are Hero, Honda, Yamaha, TVS, Kinetic, Bajaj, etc.
O.E in production department
M/s TAKATA INDIA PVT. LTD
07.2014 - 12.2015
- Line leader in P.U. Foaming & injection Moulding Production Department From July 2014 to Dec 2015.
- Also went to other Global plant of TAKATA at Indonesia of Control quality as well as rejection of our plant.
- During on Indonesia Honda manufacturing plant visited for customer complains.
- M/s TAKATA INDIA PVT LTD. Is an Indian Subsidiary of TAKATA Corporation Japan. M/s TAKATA Corporation have 46 plants in 17 Countries. M/s TAKATA having two manufacturing plant in India. The main product line is Motor Vehicle seat belt assembly, airbags, steering wheels. TAKATA have Inhouse assembly, P.U. Foaming & Injection Molding.
Education
3 Years Full time Diploma - Mech. Engineering
Govt. Polytechnic Lalitpur
01-2014
B.sc (I & II) -
01-2011
Skills
- Manufacturing leadership
- Production planning
- Workforce motivation
- Process optimization
- Gold purity control
- Loss recovery control
- Quality inspection
- Lean manufacturing
- Shop floor management
- Production reporting
- Problem solving
- Cross functional coordination
- Team leadership
- Production schedule and plan
- Monitoring
- Employee supervision
- Operational analysis
- Quality control techniques
- Product inspections
- Performance monitoring
- Quality Control
- Quality and risk assessment
- Maintenance planning
- Waste reduction techniques
- Productivity optimisation
- Continuous improvement focus
- Inventory control knowledge
- Manufacturing improvement strategies
- Quality control systems
- Budgeting and cost control
- Staff development plans
- Labour optimisation
- 5s principles
- Health and Safety regulations
- Materials procurement
- Safety protocols
- Troubleshooting specialist
- Factory maintenance understanding
- Waste reduction strategies
- Just In Time stock control
- Process Engineering
PERSONAL DETAIL
Language Known : Hindi & English
Accomplishments
- 2 Time received Best Suggestion award.
- Maximum Kaizen, suggestion award Received by TAKATA INDIA PVT ltd in 2014 & 2015 .
- Advanced from A.R Gold to quickly as result of Busting production and Gold recovery achievements 2023.
- Best plant setup achievement in Sparkling Chain Pvt Ltd.
- Streamlined workflow by consolidating lengthy processes and redundant documentation which resulted in more effective and timely completion of 2025 & 2026.
STRENGTH & HOBBIES
Challenge Accepting, Self-confidence., Hard working, Honest., Fast decision making and self-motivated., Listening music.
DECLARATION
I hereby declare that the given all above information is true the best of my knowledge & belief. Date -------- Place --------. ( ALOK KUMAR RAO)
PERSONAL DETAIL
- Mother Name : Mrs. Vimala Devi
Timeline
Production Manager
Royal Chain Ltd
07.2025 - Current
Technical & Production Manufacturing Head(Manager)
Sparkling chain Pvt Ltd
03.2024 - 06.2025
Engineer in Production & Maintenance Department.
A. R . Gold Pvt ltd
06.2017 - 03.2024
line leader of Assembly section on Production department
KEIHIN FIE PVT. LIMITED
01.2016 - 06.2017
O.E in production department
M/s TAKATA INDIA PVT. LTD
07.2014 - 12.2015
3 Years Full time Diploma - Mech. Engineering
Govt. Polytechnic Lalitpur