Anil Kumar S M
Tiptur
Summary
Head of Production, over 10+ Years of experience in Dairy industry, Ambitious Dairy Technologist who continuously exceeds both company and personal goals. Expertise in commissioning and fine tuning of newly installed processing equipment as well as food processing parameters to meet the quality standards of finished product, proven ability in continuous improvement activities in eliminating the waste and improving the efficiency of the plant, proven results in budget calculations and KPI's and achieving the targets.
Overview
13
13
years of professional experience
Work History
Head Of Production
Akshayakalpa Farms and Foods Pvt. Ltd
10.2023 - Current
- Overseeing production operations across all manufacturing locations in-house (Tiptur, Pooriyambakkam, Hyderabad, all city cross docks) and contract manufacturing units (ASA, Parag, Arya, Honey Day, AVS Argo).
- Overseeing, guiding and coordinating operations, continuously exploring cutting edge production processes, drawing up production schedules and ensuring production is cost effective.
- Creating and implementing best practice manufacturing vision, strategy, policies, processes and procedures to aid and improve business performance.
- Providing leadership to departments under control and coach, mentor and develop direct repartees and managing a high performing team that delivers continuous improvements.
- Conducting capacity planning, executing and reviewing the agreed production plan to meet daily/weekly/monthly sales and operational targets.
- Establishing workflow policies that enhance speed and efficiency without compromising product safety and integrity.
- Proactively work with product line management, engineering, service and other departments and incorporate best practices into the manufacturing environment.
- Ensuring that Environmental, Health and Safety, manufacturing and quality standards and procedures are adhered to.
- Ensuring efficiencies of man, machine and material resources to meet the desired targets.
- Co-ordinating market and other field visits to understand the routine issues and initiating appropriate corrective actions at the factory.
- Co-ordinating with R&D, QA, market teams for product trials and commercial launches.
- Daily MIS and work towards cost optimization.
- Designing, Planning and Execution of new green field and brown field projects.
- First Certified Organic Company in India looking after Fresh Dairy, Long life Dairy, Non-Dairy (Honey & VCO) and Bread and Batter operations considering Third Party Manufacturing Units.
Production Manager
Akshayakalpa Farms and Foods Pvt. Ltd
11.2022 - 09.2023
- Responsible for manufacturing packaged fluid milk and milk-based products as per company's laid down guidelines, SOP's and specifications and adherence to all statutory norms.
- Conduct capacity planning, Executing, and reviewing the agreed production plan to meet daily/weekly/monthly sales and operational targets.
- Ensure efficiencies of man, machine, and material resources to meet the desired targets.
- Shift scheduling and its compliance, effective usage, and optimized allocation of manpower for production.
- Ensure production team members adhered to QA protocols strictly and bridge effective communication between QA, production, and dispatches for timely clearance.
- Monitoring RMPM yields on daily basis and root cause analysis for the lapses and fix the process steps that cause material losses.
- Accountable for GMP and GHP across the site.
- Proactively lead in fixing up market feedback and sharing corrective action and preventive action reports by coordinating with QA and maintenance teams and sharing action taken proofs to the management.
- Co-ordinating market and field visits to understand the routine issues and initiating appropriate corrective actions to the factory.
- Co-ordinate with R&D, QA, Market Teams for new product development trials and commercial launches.
- Schedule In-house training of existing employees, new joiners, and fresh manpower recruitment.
- Monitoring RMPM material inventory and maintaining seamless communication with supportive cross functions such that production activities are smooth and uninterrupted.
- Waste disposal management and co-ordination with cross functions.
- Asset management and accountable for the domain.
- First Certified Organic Company in India looking after Fresh Dairy and Long-life Dairy productions.
Production Shift Manager
Glanbia Cheese EU
04.2022 - 11.2022
- Shift responsibility for the effective and efficient operation of a highly automated 24 / 7 Mozzarella Cheese Production and Packing Department.
- Taking ownership and accountability on shift for the department's performance against agreed targets and key performance indicators (KPIs) ensuring continuous improvement across all key operational metrics.
- Taking proactive approach in managing all aspects of production and packing on shift identifying and supporting opportunities for continuous improvement.
- Monitoring all process controls points on a continuous basis taking appropriate action as necessary to optimize and maintain product specification whilst maximizing line efficiencies and minimizing waste.
- Supporting the maintenance team to deliver best practice asset care through correct operation of process equipment and early escalation and resolution of potential issues.
- Providing clear leadership to the shift production team developing a culture of engagement through involvement and set clear standards and expectations for each direct report and hold them accountable for delivery.
- Working closely with QA Shift Technician to ensure correct clean down and site GMP standards are achieved and maintained within the department and monitor product code specifications to ensure good quality is consistently achieved.
- Monitor product quality continuously and react and report where issues arise that may affect HACCP protocols, involving Quality Team and Management.
- A major manufacturer of Mozzarella Cheese in the UK and Europe.
Asst. Manager, Milk Balance
Almarai Company
12.2020 - 02.2022
- Designing profit oriented optimized strategic plan to manage the medium to long-term company-wide supply and Demand of Milk and Milk Balance ingredients and align key business units for execution.
- Ensuring that raw milk supply and its alternative components are properly utilized to maximize margins.
- To maintain a balance in the supply and demand of raw milk and its alternative components to meet the ever-increasing Growth in the demand of dairy products.
- Providing future indications of supply surplus or shortage or any other related constraints and work with other teams to achieve a favorable solution.
- Managing Almarai bulk ingredients, trading business and ensuring development of local and international markets.
- Ensuring that raw milk stocks are maintained at optimum levels (upper and lower limits) in all locations company wide and implementing mitigating actions to keep the stocks at optimum levels.
- Responsible for using dairy production recipes that will deliver more margins for the company while balancing the milk.
- Recommending dairy production recipes that will be used as standard recipes for the yearly budget and 5-year budget plans.
- Providing long range milk balance recipe and production plans to SAP functional and SAP master data teams for system configuration and planning.
- Participation in GDT (Global Dairy Trade) events along with procurement team to procure dairy related GDT ingredients at globally fixed market price.
Senior Team Manager, CPP3 Production
Almarai Company
10.2019 - 11.2020
- Developed strategy to adopt the operational excellence environment within the CPP3, Almarai.
- Drive strategic quality plan at the operational level, defining and implementing strategic initiatives to ensure success in the deployment of operational excellence practices.
- Ensuring to align with Production process and the filling process considering all the quality and regulatory standards set up by Almarai.
- "Right First Time" strategy in achieving the production plan and on time delivery of product to related stakeholders.
- Implementing 5S in Filling and downline areas to improve the quality standards and continuous auditing to sustain the standards.
- Implementing and sustaining top loss and SIC reports and meetings to reduce the breakdowns including repeated breakdowns and improve the efficiency of production.
- Proven efficiency improvement of PTS-32 to meet world class OEE and sustain efficiency through continuous improvement tool DMAIC.
- Preparation of 5 why - Root Cause Analysis reports to understand the exact root cause analysis and placing permanent solution along with related stakeholders.
- Implementing MES in production and preparing the BOM of the recipes to align with the MES system.
- Audited the facility & identified the mandatory requirement and fulfilled it via CAPEX (Project Charter) with proper justification.
- Facilitate the manufacturing requirements on time to optimize the resources.
- Management of finance activities for manufacturing from root level.
- Schedules and coordinates flow of work within or between departments of manufacturing plant to expedite production.
- Optimize product quality ensuring that the product meets required specification and maintains its first time release.
- Maximize service to customers, right product at the right time at the right specification within the budget.
- Optimize product LIP (Loss in Process) to maximize the contribution to profitability of the operation.
- Providing all the necessary on the job training to staff to ensure all activities are conducted in a safe and efficient manner and necessary skills are maintained within the team.
- Deploy quality plan at the operational level in conjunction with the operational excellence group to provide overall quality leadership to the site.
- Manage quality and lean six sigma strategies to facilitate continuous production of products consistent with established industry standards, government regulations and customer requirements.
- Monitoring and controlling all processing related LIP within the budget as reported in SAP.
Manufacturing Analyst, Central Processing Plant-3
Almarai Company
03.2017 - 09.2019
- Provide management with the information and initiate actions which can aid to reduce losses in manufacturing.
- Perform daily yield analysis of products.
- Conduct line studies to identify opportunities to reduce LIP at different stages of manufacturing processes.
- Analyze the product rejection issues and propose corrective actions to eliminate the rejections.
Dairy Technologist, Central Processing Plant-1
Almarai Company
02.2015 - 02.2017
Technical Officer
Karnataka Milk Federation
Bangalore, Karnataka
08.2013 - 07.2014
Education
B. Tech - Dairy Technology
Dairy Science College
Gulbarga, KarnatakaSkills
- Processing
- Production
- Projects
- Business Analysis
- Quality
- Fresh Dairy Products
- Fermented Products
- Yoghurt
- Custard
- Long Life Dairy Products
- Cheese
- 5S Implementation
- Sustainability
- Root Cause Analysis
- DMAIC
- Top Loss
- SIC
- Time Management
- People Management
- Budget Preparation
- Cost Saving Planning
- Corporate Culture
- Recipe Formulation
- Product Trials
- CIP Optimization
- Process Parameters
- MS Office
- SAP
- ETQ
- Q-pulse
Accomplishments
- Proposed cost saving initiatives for the department
- Improving OEE of PTS 32 to meet world class standards
- Effectively carried out reduction in LIP by validating and optimizing the product and water purges of pasteurizers
- Reduced product reductions due to foaming issues
- Reduced 'Give-away' in all PTS fillers which reduced overall production LIP
- Chemical usage reduction by 15% at CPP1 through DMAIC
- 5S implementation in CPP3 and CPP1 to improve quality standards
- Scored 100% in SOP writing and review training conducted by operation excellence team of Almarai.
Languages
English
Hindi
Kannada
Telugu
Area Of Expertise
- Competent in processing, production, projects, business analysis and quality
- Competent in technology of fresh, fermented, yoghurt, custard, long life dairy products and cheese
- 5S implementation and sustainability
- Root cause analysis (5 why)
- DMAIC tool usage
- Top Loss and SIC
- Time management
- People management
- Budget Preparation's and Cost Saving Planning's
- Well versed in Business analysis and driving business towards profitability.
- Well adopted towards corporate culture
- Supporting new recipe formulations based on business profitability and sustainability.
- Coordinating and organizing activities and product trials in multicultural industry
- Optimizing CIP and process parameters of newly installed equipment
- Computer skills: MS-office - word, Excel, power point and outlook
- SAP, ETQ, Q-pulse
Training
- Successfully completed lean and six sigma yellow belt training conducted by Almarai Continuous Excellence Team
- Successfully completed 2 days training on CIP optimization and Process Engineering conducted by operational excellence team of Almarai
- Successfully completed all 5 modules of Permit To Work (PTW) conducted by Almarai Health And Safety Division
- Successfully completed SOP writing & review and competency assessment training conducted by operational excellence team of Almarai.
- Successfully completed EMEX training for reporting accidents and near misses conducted by Almarai Health and Safety Division
- Successfully completed 2 days training on 5 S for better work place conducted by Almarai Operation Excellence Team
- Successfully completed one-day course of First Aid, CPR and AED
- Successfully completed FOSTOC training.
- Successfully completed Internal Auditor Training.
Disclaimer
I hereby declare that the information furnished above fair & correct.
Personal Information
Available: Immediate
Timeline
Head Of Production
Akshayakalpa Farms and Foods Pvt. Ltd
10.2023 - Current
Production Manager
Akshayakalpa Farms and Foods Pvt. Ltd
11.2022 - 09.2023
Production Shift Manager
Glanbia Cheese EU
04.2022 - 11.2022
Asst. Manager, Milk Balance
Almarai Company
12.2020 - 02.2022
Senior Team Manager, CPP3 Production
Almarai Company
10.2019 - 11.2020
Manufacturing Analyst, Central Processing Plant-3
Almarai Company
03.2017 - 09.2019
Dairy Technologist, Central Processing Plant-1
Almarai Company
02.2015 - 02.2017
Technical Officer
Karnataka Milk Federation
08.2013 - 07.2014
B. Tech - Dairy Technology
Dairy Science College