Summary
Overview
Work History
Education
Skills
Accomplishments
Additional Information
Languages
Timeline
Generic
BIpin Karekar

BIpin Karekar

Pune,MH

Summary

Experienced Plant Manager adept at improving output, maximizing quality and boosting employee satisfaction with hands-on management style. Recognized as effective business manager and motivational leader. Successful manufacturing management career spanning 23 years. Dedicated plant management professional driven to maximize team productivity. Team builder versed in morale-building and efficiency-boosting strategies. Smoothly direct employees carrying out production operations to achieve demanding production goals, schedules and budget targets. Driven leader with excellent analytical, decision-making and project management abilities. Maintain employee focus and achieve quality targets with hands-on supervision. Goal-oriented Manufacturing Manager with 13 years of experience leading productive teams and increasing profitability through streamlining processes and identifying areas of improvement. Resourceful and adaptable collaborator with knowledge of enhancing operations and maintaining high standards of safety practices. Proven leader with dedication to organization and effective management.

Overview

25
25
years of professional experience

Work History

Deputy General Manager-Operations

ARDEE INDUSTRIES.
08.2023 - Current
  • Managed direction and planning for plant with focus on optimization of daily functions, exceeding customer expectations and achieving KPIs.
  • Directed employees and related programs to maximize team productivity and facility output.
  • Monitored and supported progress of plant production orders by managing shop capacity and loading functions at several facilities.
  • Organized and guided operations of production, processing and machinery according to business procedures and protocols.
  • Tracked data about all aspects of production to assess areas in need of improvement.
  • Optimized processes to maximize efficiency.

Plant Head

BPL Nigeria Ltd.
06.2022 - 07.2023
  • Plan, organize, direct and run optimum day-to-day operations to exceed our customers' expectations.
  • Increase production, assets capacity and flexibility while minimizing unnecessary costs and maintaining current quality standards.
  • Be responsible for production output, product quality and on-time shipping.
  • Allocate resources effectively and fully utilize assets to produce optimal results.
  • Implement strategies in alignment with strategic initiatives and provide a clear sense of direction and focus.
  • Monitor operations and trigger corrective actions.
  • Share a trusting relationship with work group and recruit, manage and develop plant staff.
  • Collect and analyze data to find places of waste or overtime.
  • Directed employees and related programs to maximize team productivity and facility output.
  • Reduced costs by eliminating materials waste and unnecessary labor hours.
  • Maximized plant safety through proactive strategies and well-structured training.
  • Optimized processes to maximize efficiency.
  • Managed direction and planning for plant with focus on optimization of daily functions, exceeding customer expectations, and achieving KPIs.
  • Provided direction and leadership to all levels of employees and managers.
  • Monitored and evaluated plant performance to identify areas for improvement and take corrective measures.
  • Implemented useful inventory management and tracking systems to reduce costs and improve operations.
  • Created plant policies and procedures for safe and productive operations.
  • Identified and resolved process and equipment issues to minimize production downtime.
  • Managed personnel by implementing company policies, procedures, work rules, and disciplinary action.
  • Planned operations to meet established schedules, factoring in order demands and business forecasts.
  • Evaluated employee performance and provided feedback and training as needed.
  • Implemented quality control system to review products against technical specifications and corporate standards.
  • Analyzed production data and prepared reports for senior management.

Senior Operations Manager

Chloride Metals Ltd.
05.2019 - 05.2022
  • Ensuring sufficient stock of all the raw materials and consumables to ensure production of lead ingots with quality in focus
  • Ensuring that the incoming raw materials are as per the standard quality. Even finished products need to be adhered to quality standards |
  • Overseeing maintenance of all the equipment's in the lead plant | Planning, organizing, directing and running optimum day to day operations
  • Directing and coordinating the daily operations of a manufacturing plant
  • This includes developing efficiency strategies to ensure the plant meets production goals and standards at minimal manufacturing costs |works directly with department heads to coordinate purchasing, production and distribution operations
  • Duties include instituting policies and procedures, training supervisors and administrators, maintaining a production schedule, giving performance reviews and motivating staff to meet production goals Ensure that all workings are manufactured in a correct, cost effective and timely manner in alignment with specifications and quality requirements Chalk out or improve operational systems, processes and best practices that guarantee organizational well-being
  • Purchase materials, plan inventory and ensure complete Scrap Battery Plant efficiency
  • Contribute towards the achievement of company's strategic and operational objectives
  • Examine financial data/statements and utilize them to improve profitability
  • Perform quality controls and monitor production KPIs|

Plant Manager

Mining Engineering Services SARL. Lubumbashi, DRC
08.2018 - 04.2019
  • Plan, organize, direct and run optimum day-to-day operations to exceed our customers' expectations
  • Increase production, assets capacity and flexibility while minimizing unnecessary costs and maintaining current quality standards
  • Be responsible for production output, product quality and on-time shipping
  • Allocate resources effectively and fully utilize assets to produce optimal results
  • Implement strategies in alignment with strategic initiatives and provide a clear sense of direction and focus
  • Monitor operations and trigger corrective actions
  • Share a trusting relationship with workgroup and recruit, manage and develop plant staff
  • Collect and analyze data to find places of waste or overtime
  • Commit to plant safety procedures
  • Develop systems and processes that track and optimize productivity and standards, metrics and performance targets to ensure effective return on assets
  • Address employees' issues or grievances and administer collective bargaining agreements
  • Influence and learn from below
  • Stay up to date with latest production management best practices and concepts

Production Planning Head

Zalco Ltd. Kabwe, Zambia
02.2017 - 11.2018
  • Implemented scheduled maintenance, retooling production status sheets and driving tasks to achieve scheduling effectiveness.
  • Collaborated with cross-functional teams to align production plans with customer requirements.
  • Created and implemented tracking systems to monitor progress and meet deadlines.
  • Devised and implemented efficient processes for production tracking and inventory control.
  • Implemented scheduled maintenance, retooling production status sheets and driving tasks to achieve scheduling effectiveness.
  • Implemented scheduled maintenance, retooling production status sheets and driving tasks to achieve scheduling effectiveness.
  • Adaptable and proficient in learning new concepts quickly and efficiently.
  • Inspected stocks to identify shortages, replenish supply and maintain consistent inventory.
  • Prepared and maintained comprehensive production reports to highlight production developments for management review.
  • Forecasted production schedules and adjusted plans to accommodate changes in demand.
  • Excellent communication skills, both verbal and written.

Production Manager

Myanmar Smelting And Refining Ltd.
12.2016 - 04.2017
  • Managed continuous improvement initiatives to drive gains in quality, flow, and output.
  • Resolved issues quickly to maintain productivity goals.
  • Sourced materials to keep up with production goals and meet customer demands.
  • Created streamlined production schedules and collaborated with production employees to communicate objectives and goals.
  • Standardized production procedures, job roles, and quality assurance guidelines.
  • Managed personnel by implementing company policies, procedures, work rules, and disciplinary action.
  • Monitored inventory levels and restocking schedules to avoid production delays from unavailable materials.
  • Planned operations to meet established schedules, factoring in order demands and business forecasts.

Production Manager

United Lead Ltd.
08.2015 - 11.2016
  • Overseeing production processes( Refining & Smelting Section)
  • Planning a production schedule
  • Making decisions about equipment use and maintenance
  • Implementing improvements to the production process
  • Estimating costs and preparing budgets
  • Ensuring products meet quality standards
  • Supervising and evaluating the performance of production personnel
  • Preparing production reports
  • Managed continuous improvement initiatives to drive gains in quality, flow, and output.
  • Resolved issues quickly to maintain productivity goals.
  • Created streamlined production schedules and collaborated with production employees to communicate objectives and goals.
  • Standardized production procedures, job roles, and quality assurance guidelines.
  • Reviewed work for quality and compliance with company standards and design specifications.
  • Reviewed maintenance and repair problems to determine appropriate action for resolution.
  • Managed internal operational standards and productivity targets.
  • Estimated labor requirements to support anticipated workload.
  • Managed personnel by implementing company policies, procedures, work rules, and disciplinary action.
  • Monitored inventory levels and restocking schedules to avoid production delays from unavailable materials.
  • Operated specialized equipment, gauges and instruments to track and assess gas levels.
  • Created and oversaw production schedules and adjusted as needed to meet deadlines.
  • Planned operations to meet established schedules, factoring in order demands and business forecasts.
  • Analyzed production data and prepared reports for senior management.

Operations Manager

Mittal Pigments Pvt. Ltd., India
08.2010 - 07.2015
  • Set, enforced, and optimized internal policies to maintain responsiveness to demands.
  • Devised processes to boost long-term business success and increase profit levels.
  • Implemented process improvement to shape organizational culture, optimize procedures for higher efficiency and help company evolve and grow.
  • Identified and resolved unauthorized, unsafe, or ineffective practices.
  • Established positive and effective communication among unit staff and organization leadership, reducing miscommunications, and missed deadlines.
  • Introduced new methods, practices, and systems to reduce turnaround time.
  • Negotiated contracts with vendors and suppliers to obtain best pricing and terms.
  • Developed systems and procedures to improve operational quality and team efficiency.
  • Managed inventory and supply chain operations to achieve timely and accurate delivery of goods and services.
  • Analyzed and reported on key performance metrics to senior management.
  • Supervised operations staff and kept employees compliant with company policies and procedures.
  • Developed and maintained relationships with external vendors and suppliers.
  • Increased profit by streamlining operations.
  • Reduced process bottlenecks by training and coaching employees on practices, procedures, and performance strategies.
  • Reported issues to higher management with great detail.
  • Trained and guided team members to maintain high productivity and performance metrics.
  • Reduced operational risks while organizing data to forecast performance trends.

Deputy Production Manager

Tandon Metals Pvt. Ltd. (Now Chloride Metals Ltd.
06.2002 - 07.2010
  • Resolved issues quickly to maintain productivity goals.
  • Created streamlined production schedules and collaborated with production employees to communicate objectives and goals.
  • Sourced materials to keep up with production goals and meet customer demands.
  • Reviewed work for quality and compliance with company standards and design specifications.
  • Managed internal operational standards and productivity targets.
  • Managed continuous improvement initiatives to drive gains in quality, flow, and output.
  • Standardized production procedures, job roles, and quality assurance guidelines.

Production and Planning Supervisor

Jayshree Die Casting Pvt. Ltd
02.1999 - 05.2002
  • Conducted audit inspections and independent checks to verify parts and materials.
  • Verified overall customer plans to achieve sales and operations objectives.
  • Devised sales plans and inventory plans for customers by product.
  • Collaborated with company leaders to support consistency and best practices.
  • Generated and analyzed POS reports to review sales by location and time for future planning.
  • Planned resources, conducted costing activities, and managed bid and proposal phases.
  • Monitored processes and procedures, making sure company met compliance regulations.

Education

High School Diploma -

SVPM
Baramati
04.1998

Skills

  • Verbal and Written Communication
  • Raw Product Testing
  • Production Order Review
  • Product Standards Establishment
  • New Process Development
  • Decision Making
  • Processing Operations Review
  • Production Schedule Review
  • Resource Management
  • Process Planning
  • Production Problem Resolution
  • Time Management
  • Budget Development
  • Staffing Requirement Determination
  • Product Planning
  • Schedule Management
  • Employee Performance Reviews
  • Team Training
  • OSHA Regulations
  • Equipment Maintenance
  • Workflow Management
  • Equipment Installation
  • Team Management
  • Plant Maintenance
  • Equipment Operation
  • Lean Manufacturing Principles
  • Forklift Operation
  • Process Automation
  • Staff Training and Development
  • Waste Reduction
  • Production Planning
  • Safety Management
  • Environmental Monitoring
  • Operational Excellence
  • Team Building and Development
  • Resource Coordination
  • ISO Compliance
  • Production Scheduling
  • Continuous Improvement
  • Cost Controls
  • Cost Reporting

Accomplishments

    INTERNATIONAL EXPOSURE

    Iranian Lead Refiners Co., Iran: Rendered consultancy for smelting and refining

    ELMI.J.I.LLC, Armenia: Rendered consultancy for smelting and refining

    MetPak Industries, Pakistan (Karachi) Rendered consultancy for smelting and refining

    Pagrik Ethiopia PLC (Ethiopia) Rendered consultancy for smelting and refining

    Azar Battery Co. (Urmiya, Iran) Testing Raw Material and Solve Process Problem

    Albroz Behin Bazafarin (Iran) Business Meeting

    Eternity Technologies (Ras Al Khaimah, UAE) Testing of Supplied Material

    Ducap (Dubai, UAE) Supplied Material Trial Given Satisfactory

    National Lead Smelting Co. LTD. (Rasass,Riyadh) Rendered consultancy for smelting and refining

    Riyadh Cables Group of Companies (Riyadh) Supplied Material Trial Given Satisfactory

    Sun Metals Group (Ajman, UAE) Rendered consultancy for refining

    United Lead Ltd. (Jeddah, KSA) Production Manager

    Zalco Ltd.(Kabwe,Zambia) Lead Plant Head.

    Success Africa Ghana Ltd.(Ghana) Technical Consultant

    Myanmar Smelting & Refining (Yangon) Technical Consultant

    Mining Engineering Services,DRC Lead Plant Manager

Additional Information

Techno- Commercial Production and Project Management Professional |Strategic Planning Head for lead Smelting and Refining Projects | 22+ years of Global Experience| Expertise predominantly in Pre-Sales Activities and Enhancing Production Processes| Base metals & mining and metallurgical engineering industry| Seeking Leadership Role |Expertise in Silver recovery and bismuth removal.

Oxyfuel Technology Implementation in Chloride Metals Ltd.

Languages

Hindi
Advanced (C1)
Marathi
Bilingual or Proficient (C2)
English
Upper intermediate (B2)

Timeline

Deputy General Manager-Operations

ARDEE INDUSTRIES.
08.2023 - Current

Plant Head

BPL Nigeria Ltd.
06.2022 - 07.2023

Senior Operations Manager

Chloride Metals Ltd.
05.2019 - 05.2022

Plant Manager

Mining Engineering Services SARL. Lubumbashi, DRC
08.2018 - 04.2019

Production Planning Head

Zalco Ltd. Kabwe, Zambia
02.2017 - 11.2018

Production Manager

Myanmar Smelting And Refining Ltd.
12.2016 - 04.2017

Production Manager

United Lead Ltd.
08.2015 - 11.2016

Operations Manager

Mittal Pigments Pvt. Ltd., India
08.2010 - 07.2015

Deputy Production Manager

Tandon Metals Pvt. Ltd. (Now Chloride Metals Ltd.
06.2002 - 07.2010

Production and Planning Supervisor

Jayshree Die Casting Pvt. Ltd
02.1999 - 05.2002

High School Diploma -

SVPM

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BIpin Karekar