Durgesh Prakash Singh
Mau
Summary
Textile & Carpet Technologist with 12+ years of experience in Process Development, Synthetic yarn processing,Weaving,Tufting,Coating,Dyeing, finishing,Process Control, Quality Management, Quality Compliance, Operations Management.
Overview
13
13
years of professional experience
6
6
years of post-secondary education
Work History
Manager Operations, Process Development & TQM
PT. Rainbow Indah Carpet
Jakarta
05.2025 - Current
- Lead product development and process improvement initiatives for coating, finishing, and synthetic-based products.
- Lead Devloper for Carpet Tiles, Artificial Grass, Broad Loom Carpet, Tufted Rugs, Printed Rugs, Specialized Yarn.
- Handle Tufting & Coating operations including tufting design & specifications, latex formulation, viscosity control, and adhesion optimization.
- Drive process standardization and scale-up of development trials from pilot stage to bulk production.
- Monitor and control finishing processes including heat setting, dimensional stability, and surface enhancement.
- Coordinate with R&D, production, and quality teams for new product development and sample approvals.
- Implement lean manufacturing, CAPA, and FMEA for process and quality improvements.
- Conduct root cause analysis of defects such as coating failure, shade variation, and finishing issues.
- Developed new products based on market requirements and buyer specifications.
- Conducted trials on coating formulation and chemical optimization to improve product performance.
- Worked on adhesion strength, coating durability, and finishing quality enhancement.
- Involved in sample development, testing, and evaluation as per international standards.
- Ensured smooth transition from development stage to mass production.
- Reduced tufting wastage from 3.5% to 2.5%.
- Improved productivity from 60% to 70% efficiency.
- Minimized heat setting defects and lot variation significantly.
- Reduced downgrade in tufting by 1% via process optimization.
- Improved coating performance and reduced backing wastage.
Deputy Manager of TQM & Process Control
Welspun Living Ltd
Hyderabad
05.2023 - 04.2025
- Managed daily operations to ensure efficient workflow and quality standards.
- Coordinated team activities to align with project timelines and objectives.
- Developed training materials for staff onboarding and skill enhancement.
- Data collection and defect analysis.
- CAPA, FMEA, PDCA
- Product documentation and report makings.
- Technical audits management.
- Product Auditing.
- Buyer requirements study and there implementation.
- Internal Auditing and Inspection.
- Inline and final inspection.
- Product testing and approval.
Assistant Manager, Process Development finishing
BRFL
Tarapur
04.2022 - 04.2023
- Process Development and finishing root finalization according fabric quality.
- Production recipe finalization.
- Production parameter finalization for mechanical finishing.
- New row material and chemical trail and finalization.
- Data collection and defect analysis.
- CAPA and Process Improvements.
Manager, Process Control And TQM
Diamond Export
Agra
11.2020 - 10.2021
- Products documentations and report review.
- Inline and final inspection.
- Data collection and defect analysis.
- Product parameter monitor and product specifications finalization.
- Internal and external products testing.
- Internal and external audits management's.
- New Products development and approval.
- Preparation of technical specifications sheets for new development.
- Finalization of dimensions and weight of products packaging.
- Manpower training and development.
- Row material testing and approval.
Assistant Manager, Process Control And TQM
Welspun Flooring Ltd.
Hyderabad
12.2018 - 05.2020
- Products documentations and report review.
- Inline and final inspection.
- Data collection and defect analysis.
- Product parameter monitor and product specifications finalization.
- Internal and external products testing.
- Internal and external audits management's.
- New Products development and approval.
- Preparation of technical specifications sheets for new development.
- Finalization of dimensions and weight of products packaging.
- Manpower training and development.
- Row material testing and approval.
Senior Executive, Processing.
CGPL
Vapi
06.2013 - 11.2018
- Shift planing and production control.
- Recipe finalization of yarn dyeing and fabric finishing department.
- Manpower planing in dyeing department.
- Data collection and defect analysis.
- Production documentations.
- Products technical specification finalization.
- Lab report review of production.
- Shade matching and correction.
Education
B-Tech - Textile & Carpet Technology
Indian Institute of Carpet Technology
SRN Bhadohi, India 07.2010 - 04.2013
Diploma - Textile & Handloom Technology
IIHT Guwahati
Guwahati , India 07.2006 - 04.2009
Skills
- Synthetic Fiber Processing (PP, Polyester, Nylon)
- Coating Technology (Latex, Precoat, Secondary Backing)
- Textile Finishing & Heat Setting
- Product Development & Sampling
- Chemical Process Optimization
- Shade Consistency & Defect Analysis
- Process Scale-up (Development to Bulk Production)
- Quality Assurance & Testing
- Lean Manufacturing
- CAPA
- FMEA
- Production Planning
- Process Control
- Dyeing & Finishing Process Understanding (Synthetic Textiles)
- Coating Formulation & Application Techniques
- Yarn Processing (BCF, POY, Heat Setting)
- Tufting & Carpet Manufacturing Technology
- Testing & Quality Evaluation (ISO/ASTM Standards)
- SAP & Production Planning Systems
- Root Cause Analysis
- Continuous Improvement
Process Improvement Achievements
- Reduced tufting wastage from 3.5% to 2.5%.
- Improved productivity from 60% to 70% efficiency.
- Minimized heat setting defects and lot variation significantly.
- Reduced downgrade in tufting by 1% via process optimization.
- Improved coating performance and reduced backing wastage.
Development and RnD Experience
- Developed new products based on market requirements and buyer specifications.
- Conducted trials on coating formulation and chemical optimization to improve product performance.
- Worked on adhesion strength, coating durability, and finishing quality enhancement.
- Involved in sample development, testing, and evaluation as per international standards.
- Ensured smooth transition from development stage to mass production.
- Data collection and analysis from sampling to mass production.
- Consumption monitoring from sampling to mass production.
- New development products specifications and production parameter finalization.
- Products process root finalization.
- Dimensions and weight finalization of products packaging.
- Products audit and defect analysis.
- CAPA for running Products Quality issues.
Core Expertise
- Synthetic Fiber Processing (PP, Polyester, Nylon)
- Coating Technology (Latex, Precoat, Secondary Backing)
- Textile Finishing & Heat Setting
- Product Development & Sampling
- Chemical Process Optimization
- Shade Consistency & Defect Analysis
- Process Scale-up (Lab to Bulk Production)
- Quality Assurance & Testing
- Lean Manufacturing, Kaizen, CAPA, FMEA
- Production Planning & Process Control
Languages
Hindi
Beginner
A1
English
Beginner
A1
Timeline
Manager Operations, Process Development & TQM
PT. Rainbow Indah Carpet
05.2025 - Current
Deputy Manager of TQM & Process Control
Welspun Living Ltd
05.2023 - 04.2025
Assistant Manager, Process Development finishing
BRFL
04.2022 - 04.2023
Manager, Process Control And TQM
Diamond Export
11.2020 - 10.2021
Assistant Manager, Process Control And TQM
Welspun Flooring Ltd.
12.2018 - 05.2020
Senior Executive, Processing.
CGPL
06.2013 - 11.2018
B-Tech - Textile & Carpet Technology
Indian Institute of Carpet Technology
07.2010 - 04.2013
Diploma - Textile & Handloom Technology
IIHT Guwahati
07.2006 - 04.2009