HEMANT BHUTTADA
Plant Head
Silvassa
Summary
Passionate People Leader with strong expertise in manufacturing operations and cope up with change. Lead the several COGS improvement initiatives for bottom line improvement. Well diversified experience and proven track record in sectors like Automobile, FMCG, Beverages, & Flexible packaging. Rich experience in Brownfield and Greenfield manufacturing setup and delivered targeted revenue & profit objectives for the organization. Organized and dependable candidate successful at managing multiple priorities with a positive attitude. Willingness to take on added responsibilities to meet team goals.
Overview
22
22
years of professional experience
5
5
Languages
Work History
Plant Head
Huhtamaki India Limited
1 2022 - 3 2024
- Leading India's 2nd largest manufacturing facility (profit center) of Huhtamki India Ltd, serving domestic & export customers with revenue contribution of Rs700 Cr ($85MMUSD)
- Site specializes in product like Flexible, Shrink Sleeves, Pouches, Tube Laminates & specialized items, with total capacity of 21KT
- Leading the team of 780 + members (Onroll + FTEs) including 6 Senior managers with average experience of 21 years.
- Boosted overall plant performance by analyzing key performance indicators and driving continuous improvement initiatives.
- Trained in and implemented emergency response procedures to protect team members and property.
- Created plant policies and procedures for safe and productive operations.
- Empowered team members by delegating responsibilities according to individual strengths and areas of expertise.
- Built strong relationships with customers through positive attitude and attentive response.
- Maintained an inclusive and diverse team culture, promoting respect and understanding among all members.
- Optimized customer experience by delivering superior services and effectively troubleshooting issues.
- Streamlined workflows for increased efficiency, reducing turnaround times for critical tasks.
- Implemented employee recognition programs that boosted morale and increased retention rates within the team.
- Cultivated positive relationships with vendors to deliver timely and cost-effective supply of services and materials.
- Established open and professional relationships with team members to achieve quick resolutions for various issues.
- Assisted in recruitment of new team members, hiring highest qualified to build team of top performers.
- Provided ongoing support to direct reports, addressing concerns or questions promptly so they could remain focused on their tasks.
- Proven ability to learn quickly and adapt to new situations.
- Demonstrated respect, friendliness and willingness to help wherever needed.
Plant Head (DGM)
Zydus Wellness Ltd
04.2018 - 01.2022
- Leading the manufacturing facility of Brand Nutralite serving domestic and export which contributes revenue of 350 Cr ($44MMUSD)
- Leading site total manpower of 280 (Onroll & FTE) people
- Site has a very wide range of products like Fat Spread, Mayonnaise, Chocolate Spread & Sugar free Chocolate Bars, with a total capacity of 20KT with 6 automated imported manufacturing lines.
- Fostered a culture of innovation by encouraging employee suggestions for process improvements and rewarding top performers.
- Established positive relationships with suppliers to obtain timely deliveries of materials and products.
- Upgraded plant equipment with state-of-the-art technology that increased throughput rates without sacrificing product quality.
- Led, trained and coached plant staff to facilitate high levels of productivity and quality.
- Oversaw capital projects, ensuring timely completion within budget constraints and minimal disruption to operations.
Manufacturing Manager
PepsiCo India Holdings(P) Limited
01.2017 - 04.2018
- Led Manufacturing Operations of the plant contributing the revenue of INR 240Cr/Annum with four high-speed fully automated packaging lines.
- Coordinated with other departments to align production with customer requirements.
- Supervised production team, keeping production schedules on track to meet tight deadlines.
- Planned operations to meet established schedules, factoring in order demands and business forecasts.
- Oversaw inventory management, ensuring optimal levels were maintained to meet production demands without excessive stockpiling or shortages.
- Oversaw routine maintenance programs and scheduled service to keep equipment functioning at peak levels.
- Enhanced product quality by performing regular audits, enforcing strict adherence to industry standards, and implementing corrective actions when necessary.
- Created and oversaw production schedules and adjusted as needed to meet deadlines.
AM Manufacturing
Mondelez India Foods (P) Ltd
10.2012 - 12.2016
- Lead & owned 2 molded line operation having capacity of 20MT/day finished goods chocolate. Lead 140+ people (Unionized) & 4 direct shift managers.
- Developed long-term strategies for manufacturing operations, aligning with company goals and objectives to drive sustainable growth.
- Supervised production team, keeping production schedules on track to meet tight deadlines.
- Changed equipment over to new products to meet customer requirements.
- Scrutinized production output and identified areas for improvement.
- Enforced health and safety protocols to promote safe working environment.
- Applied lean principles to improve workflow and quality and reduce waste.
Team Leader
ITC Limited (Foods Division)
6 2005 - 10.2012
- Learn, Lead, delivered quality product Sunfeast Biscuits from 3 plants & 3 different geographies in country.
Responsible For: -
Contract Unit process standardization, costing & commercial production stabilization.
Manage 3 lines (Cutting, Molding & Sandwiching) operation having capacity of 120MT/Day.
Good experience & confidence on process like Mixing, Baking & Packing with all type of SKU & packs. - Oversaw the successful completion of multiple high-priority projects, ensuring timely delivery.
- Championed employee development programs that led to internal promotions and increased retention rates.
- Enhanced problem-solving skills within the team through facilitating brainstorming sessions and encouraging creative thinking.
Engineer
TATA Motors Ltd
08.2002 - 05.2005
- To achieve target production of Indica shop Engine Manufacturing, by reducing unplanned downtime & losses. Responsible for Line Mechanical Maintenance part & its efficiency improvement
Lead unionized operator team of 18 team member. - Assisted senior engineers in developing innovative solutions for complex engineering problems.
- Maintained an organized workspace conducive to effective problem-solving, maximizing productivity during time-sensitive projects or deadlines.
Education
Bachelor of Engg. (Mechanical Engineering) -
Govt. College of Engg. Amaravati (MS)
D.M.E (Diploma in MECH) - undefined
MSBTE, (V.Y.W.S. Poly. Badnera. Maharashtra)
Skills
Strategic Operations management
undefinedAccomplishments
- Huhtamki India Ltd :-
- Plan, organize, direct, & run optimum day to day operations to exceed our customers' expectations, DIFOT @ > 95%.
- Consistent Double digit Operating Profit from past 2 years.
- YOY 25% wastage reduction at the site
- Improved OEE by 22% in last 2 years, organic capacity increased by 1.5KT.
- Customer complaints reduce by 30% & customer rebate reduce by 45%.
- Leading strategic project Capex plan of 139Cr of sustainable product solution.
- Productivity delivered consistently more than 5 MN INR /month & improve cost.
- Launched and Implemented TPM at the site bringing the cultural shift with high focus on Continuous Improvement & High-Performance Culture.
- Safety culture established, PLT Gemba, introduce BBS at site, PPE standardization
- Coordination & collaboration with Sales & Supply Chain team for high customer satisfaction and on time fulfillment.
- Introduced a Cross Functional Platform between commercial, Planning, Operations & Quality to ensure smooth coordination between functions mitigating the Operations delays resulting into customer satisfaction improvement by 6%.
- Sustainability front roof top solar installed which generates 9% of total electricity Units, water wastage reduce by 30%.
- Zydus Wellness Ltd :-
- Plant get Gold Award in NAMC (National Award for Manufacturing Competitiveness) led by IRIM (International Research Institute for Manufacturing), under my leadership.
- Plant ranked & qualified 1st in Zydus group out 33 plants for delivering of 24MN productivity, SLIM (Strategic Lean Integrated Manufacturing).
- Site OEE improved by 25% in two years which improves capacity by 90MT /month.
- Lead project 55 Cr of Mayonnaise & Fat Spread & Sugar free Chocolate, which added 240MT /month volume from plant.
- 6 NPD product successfully qualified, delivered & supplied to market on time.
- Plant safety Score improve from 66% to 82% by systematically working on all area.
- Strategic & sustainability project lead like express feeder line & Solar roof top.
- Manpower optimization initiative of 18 workmen / day, through automation at packing area.
- Pepsico India Holdings (P) Ltd :-
- Lead quality Assurance program, AIB & QAS Audit & CRQS Score improvement plan.
- Ensured the EHS compliances with Zero Safety incident by embedding the processes in culture
- Responsible for people processes, site engagement programs and capability building.
- Responsible for the inventory management & its optimization
- Monndelez India Foods (P) Ltd :-
- Lead & owned 2 molded line operation having capacity of 20MT/day finished goods chocolate.
- Lead 140+ people (Unionized) & 4 direct shift managers.
- Both chocolate lines Production Planning, Scheduling & execution of almost 7SKU's & 4 Types.
- Line OEE governance as per target, prepare plan to achieve, improved by 30%.
- Lead TPM AM pillar of 2 moulded Lines & E&T pillar of site which have strength of 900+ people.
- Drive all 6 SGA to achieve line KPI's through KAI like CI, Abnormality, Centre Lining& capability.
- Build& drive HPWS (High Performance Work System) culture in plant which gives HPO.
- Product material Yield improved from 95.8% to current 97.4% without any investment.
- At Quality Circle Forum achieved '6 GOLD' Award & it helps to motivate team, teambuilding.
- ITC Limited :-
- Learn, Lead, delivered quality product Sunfeast Biscuits from 3 plants & 3 different geographies in country (Unionized)
- Contract Unit process standardization, costing & commercial production stabilization.
- Manage 3 lines (Cutting, Molding & Sandwiching) operation having capacity of 120MT/Day.
- Good experience & confidence on process like Mixing, Baking & Packing with all type of SKU & packs.
- Line production capacity improvement by 7.5% through kaizen at baking process & at Oven.
- Raw Material Yield improvement from 97% to 97.9% including handling to uses.
- Over packing reduction from 5% to 3.5% of cutting line.
- HACCP implemented in Bangalore new biscuit plant to ensure & comply process & product food safety.
Behavioral Competencies
- Leadership & Visionary
- Belief in Teamwork & Collaborative
- Self-Motivator & Passionate
Timeline
Plant Head (DGM)
Zydus Wellness Ltd
04.2018 - 01.2022
Manufacturing Manager
PepsiCo India Holdings(P) Limited
01.2017 - 04.2018
AM Manufacturing
Mondelez India Foods (P) Ltd
10.2012 - 12.2016
Engineer
TATA Motors Ltd
08.2002 - 05.2005
Plant Head
Huhtamaki India Limited
1 2022 - 3 2024
Team Leader
ITC Limited (Foods Division)
6 2005 - 10.2012
Bachelor of Engg. (Mechanical Engineering) -
Govt. College of Engg. Amaravati (MS)
D.M.E (Diploma in MECH) - undefined
MSBTE, (V.Y.W.S. Poly. Badnera. Maharashtra)
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