Amit Kumar Rathi
Ghaziabad
Summary
Results-driven Manufacturing Unit Head with over 20 years in operations management within small to medium manufacturing environments. Developed and implemented process improvements to minimise waste, reduce costs, and enhance quality. Established quality control and safety programmes, fostering proactive team participation. Managed maintenance activities to minimise downtime, ensuring operational effectiveness and focused team alignment on production goals.
Overview
2
2
Languages
1
1
Certification
20
20
years of professional experience
Work History
Manufacturing Unit Head
Dharampal satyapal group Limited
Noida, UP
02.2023 - Current
- Oversaw manufacturing Operations and managed 10 direct and 350+ employees including contractual workers for Food Processing.
- Oversaw manufacturing and maintenance processes, ensuring operational efficiency and effectiveness.
- Managed overall maintenance activities, minimising breakdowns and downtime to enhance operational effectiveness.
- Track record of devising, evaluating, and implementing continuous process improvements to minimise waste and reduce costs while maximizing quality and yield.
- Established effective quality control and safety programs, encouraging proactive participation across the manufacturing floor.
- Established production schedules, defined staffing requirements, and implemented optimized procedures (Effective Utilization of 4M’s).
- Developed a scheduling mechanism for RM-PM usage, improving product quality, reducing waste and rejections, and balancing consumption variance as per SOP/BOM.
- Established maintenance schedules and prioritised tasks based on machine requirements to optimise operational efficiency.
- Coordinated team efforts to ensure adherence to daily plans compared to actual outcomes, promoting accountability.
- Ensured adherence to budgeted labour, power, and fuel costs by implementing cost-saving initiatives and process improvements.
- Devised a mechanism to improve process/food hygiene as per FSMS for different certification audits and for both food process & people health & safety.
- Ensured compliance with audit and certification standards by coaching employees on maintaining specifications.
- Coordinated the planning and commissioning of new projects.
- Implemented & Monitoring SAP Modules to monitor Consumption Variance, Plan Vs. Actual, Maintenance Schedule, Spare Parts Consumption and Availability through SAP Modules.
- Formulating SOPs and monitoring KPA for process automation & stabilization.
- Conducting DMS with Process & Other Concerned Team for the achievement/GAPs and Developed & Coached Team on to eliminate causes through proper RCA and to take CAPA.
- Reviewed individual performance metrics to identify necessary training and development opportunities.
- Excellent communicator; success building cohesive teams focused on production goals, safety, and throughput.
- Scheduling training & Identifying Key People & making their retention and succession plan to improve production.
- Scheduling training & Identifying Key People & making their retention and succession plan to improve production.
Manufacturing Assistant General Manager
Bikano Foods Private Limited
Greater Noida
11.2019 - 01.2023
- Heading Manufacturing Operations (Namkeen, Nuts & Mixtures) of 2 Units in Greater Noida.
- Notable Accomplishments:
- Productivity increased from <80% to >95% through Calibration and Optimization of Bottle Neck of the Processes.
- Reduced process wastage from 1.75% to 0.70% per kg through kaizen, training and awareness on handling processes and other process improvement activities.
- Reduced Manpower Cost (Variable Cost from Rs. 3.75 Per Kg to Rs. 2.70 Per Kg) through Manpower Restructuring & Process Automation.
- Achieved reduction in consumable cost from 1.75 rupee per kg to 0.90 paisa per kg through targeted cost management strategies.
- Initiated and led multiple process improvement projects, including kaizen, 5S, GMP and GHP, to enhance manufacturing efficiency.
- Conducted training sessions to enhance people productivity and multiskilling within the team.
- Developed a mechanism to eliminate causes through proper RCA and ensured CAPA.
Team Leader
Hindustan Coca- Cola Beverages
01.2010 - 11.2019
- Handled Beverage Manufacturing Operations of 5 Beverage Lines - 2 RGB of 600 BPM, 1 RGB- SWING OF 600BPM, 1 HOTFILL PET OF 750BPM & 1 CSD PET OF 600 BPM.
- Improved Productivity and Reduced Break Down and Losses of Filler, Bottle Washer & Pelletizer- Subject Matter Expert, Proactive in Tracking Abnormalities, Tag Age and its mitigation.
- Utilised lean manufacturing and six-sigma methodologies to improve operations.
- Executed multiple process improvement projects- Kaizen, 5’s, GMP & GHP to improve productivity.
- Reduced unwanted breakdown to maximise plant productivity and developed mechanism for breakdowns' root cause analysis, corrective actions and implementation.
- Effective in Scheduling & Executing Preventive Maintenance of Machine to improve Break Downs.
- Proactive in conducting DMS & TPM with team members and concerned departmental team on the achievement of daily targets and GAPs.
- Highlighted key contributions to operational success.
- Utilised manpower and machinery to manage budgeted labour, power and fuel costs.
- Enhanced yields for syrups, crown, RMPM and broken bottles.
- Effective in maintaining ROL & ROI of Spare Management.
- Master User & Trainer for Implementation of SAP.
Sr. Engineer Production
Allied Nippon Private Limited
10.2006 - 01.2010
GET- Production
Honda Motorcycle & Scooters Limited
07.2006 - 10.2006
Education
B. Tech - Mechanical Engineering
UPTU
12th -
Public Inter Collage
Bulandsahar, UP10th -
Public Inter Collage
Bulandsahar, UPSkills
- Lean Manufacturing
- JIT production
- Total Quality Management
- Process improvement
- Quality control
- Cost Control
- Cost reduction
- Regulatory Compliance
- Compliance auditing
- P&L Accountability
- Production scheduling
- Equipment maintenance
- SAP implementation
- Team building
- Continuous improvement
- Safety management
- Team leadership
- Team Building & Training
- Training and development
- Project planning
- Performance management
- Communication skills
- Problem-solving
- Analytical and critical thinking
- Active listening
- Commitment to excellence
- Leadership
- Team building
- Commitment to excellence
- Analytical and critical thinking
Language
Hindi
English
Certification
- FoSTaC Training & Certification, Bikano Foods, 2021
- Pneumatic System Training & Seminar, Festo India, 2015
- 5s, TPM Training & Seminar, HCCB, 2014
- Six Sigma Training & Seminar, Moser Bear, 2011
Custom
25 LPA
Timeline
Manufacturing Unit Head
Dharampal satyapal group Limited
02.2023 - Current
Manufacturing Assistant General Manager
Bikano Foods Private Limited
11.2019 - 01.2023
Team Leader
Hindustan Coca- Cola Beverages
01.2010 - 11.2019
Sr. Engineer Production
Allied Nippon Private Limited
10.2006 - 01.2010
GET- Production
Honda Motorcycle & Scooters Limited
07.2006 - 10.2006
B. Tech - Mechanical Engineering
UPTU
12th -
Public Inter Collage
10th -
Public Inter Collage