Summary
Overview
Work History
Education
Skills
Certification
Accomplishments
Language
Custom Section
Timeline
Generic
KALBE MUSTAFA

KALBE MUSTAFA

Mumbai

Summary

A seasoned HSE and Manufacturing professional with over 17 years of progressive leadership experience, including 13 years with Asian Paints, a market leader in the paint industry. Recognized as a dynamic HSE Operations and Plant Safety leader with extensive expertise in chemical manufacturing, high-risk operations, polymers, construction chemicals, resins, and hazardous material environments. Proven ability to lead multi-site EHS functions, establish robust safety governance frameworks, and drive a strong Zero Harm culture across large and complex manufacturing operations.

Overview

5
5
years of professional experience
1
1
Certification

Work History

Manager HSE, Compliance & Operations

Pidilite Industries Limited
Mumbai
02.2023 - Current
  • Led cluster-level EHS strategy across multi-state and international operations, achieving 100% statutory compliance with zero major non-conformities during audits.
  • Drove Zero Harm Culture initiatives through BBS, SUSA, and HARP deployment, resulting in zero recordable and first aid incidents, and improved workforce safety engagement.
  • Standardised Job Safety Analysis (JSA) across sites, enhancing risk identification quality and reducing unsafe conditions.
  • Spearheaded manufacturing experiments and safety benchmarking initiatives, contributing to the development of model plants, and improving overall EHS maturity scores across sites.
  • Conducted HAZOP, QRA, and implemented CCPS and RBPS guidelines to check the effectiveness of process safety in new operational plants.
  • Implemented waste minimisation and sustainability projects, leading to a 50% reduction in waste generation and significant cost savings in disposal.
  • Strengthening internal audit systems and regulatory readiness, achieving consistent audit scores above 90%, and improved compliance tracking efficiency.
  • Drove capability building through a role-based learning programme, improving training effectiveness (Kirkpatrick Levels 3 and 4), and increasing on-ground learning journeys across all the manufacturing plants by 90%.

Leadership impact.

  • Known for high ownership, structured execution, and influencing cross-functional teams.
  • Actively builds capability through coaching, training, and leadership engagement.
  • Drives a proactive safety culture rather than reactive compliance.
  • Developed an AI-based chatbot to enhance awareness of EHS SOPs on the shop floor, incorporating interactive learning methods such as MCQs, case studies, and role plays, to simulate real-life scenarios for workers and staff.

Manager EHS

Uflex Limited
Noida
09.2021 - 03.2022
  • Implemented process safety protocols for chemical storage and handling.
  • Developed the On-Site Emergency Plan (OSEP) and crisis response systems.
  • Reduced hazardous waste by 50% through regeneration and reuse initiatives.
  • Managed the international operations of Russia and Egypt.
  • Conducted a LOPA assessment for exothermic reactions and identified the areas for improvement based on CCPS, RBPS 4 PILLARS, and 20 elements.
  • Ensured implementation of IS 3594: 1991 in warehouses.

Sr. Manager Safety

DSM Firmenich- DRT Anthea
Mumbai
03.2022 - 02.2023
  • Developed and implemented plant-wide safety manuals and documentation systems.
  • Conducted CMR (Carcinogenic, Mutagenic, Reproductive toxic) risk assessments.
  • Improved reporting culture through behaviour-based safety and incentive programme.
  • Advised senior management on implementing BSC standards to enhance safety culture and stakeholder engagement, targeting the Sword of Honour to boost investor confidence, and drive business growth.

Assistant Manager

Asian Paints Limited
01.2021 - 01.2022
  • Transitioned from Production to EHS leadership, bringing a strong operational understanding.
  • Improved OEE from 0.87 to 1.11 through process optimisation.
  • Led waste reduction and solvent recovery initiatives.
  • Delivered award-winning improvements in cycle time and material efficiency.
  • Conducted HAZOP and QRA for the monomers such as styrene, MMA, BA, and EHA.
  • Considered MCLS for styrene monomer to ensure the people's occupational health and safety around the plants.
  • Developed an incident investigation manual for the complete plant, considering the government standards.
  • Developed activity-wise LOTO equipment format for easy understanding and control.
  • Conducted an aspect impact study for the complete plant operations.
  • Ensured 100% legal compliance by conducting a self-assessment of legal licences.

Education

Post Graduate Diploma - Industrial Safety

Central Labour Institute

Master's - chemistry

Allahabad University

PGDM - Operations

Skills

  • Process Safety and Risk Engineering
  • Manufacturing and Operational Excellence
  • Major Accident Hazard Management
  • Incident Investigation and Root Cause Analysis
  • Contractor and Project HSE
  • Emergency Response and Crisis Management
  • Fire, explosion, and chemical risk
  • PTW
  • LOTO TO
  • SIMOPS
  • ISO 45001
  • ISO 14001
  • ISO 9001
  • Behavioural Safety and Cultural Transformation
  • Sustainability and waste reduction
  • Team Leadership and Capability Development
  • Chemical and manufacturing excellence
  • ERP and Financial Systems, SAP
  • AI impact on EHS
  • Productivity tools: Microsoft Excel
  • Microsoft Word
  • Microsoft PowerPoint

Certification

  • NEBOSH IGC- NIST
  • IOSH- BSC
  • Internal Safety Auditor recognized by BSC

Accomplishments

  • Led HSE for 7 plants + 5 hazardous job work sites with flammable materials having production capacity more than 8000MT/Month.
  • Led organization-wide learning journey tracking, feedback cycles, and Kirkpatrick-based effectiveness assessments with clear KPIs.
  • Improved incident performance via BBS, SUSA & HARP safety programs.
  • Implemented LOTOTO, PTW enhancement & confined space safety systems.
  • Reduced hazardous waste by 50% through chemical regeneration processes.
  • Developed Emergency Response Plans for fire, explosion & toxic releases.
  • Managed contractor HSE for 950+ workforce in high-risk zones.
  • 50% reduction in reactor cleaning process by change in Process.
  • Contents development for E-learning module based on Process Safety Management.
  • Award-Winning Initiatives - Cycle time reduction & material recovery techniques.
  • Led plant layout modifications, optimizing space utilization and streamlining processes to increase production capacity and reduce manufacturing costs.
  • Led operations for Construction Chemical & Waterproofing Plants with a capacity of 72,000 MT per annum and a sales turnover of Rs. 100 Cr, ensuring optimal resource utilization, quality compliance, and statutory adherence.
  • Implemented cost reduction strategies, successfully reducing manufacturing costs from Rs. 7.7 per kg to Rs. 0.97 per kg, through process optimization and waste elimination.
  • Led end-to-end plant operations, supply chain, and manufacturing for ROFF adhesive, grout, and construction chemical products.
  • Delivered high-impact technical trainings on chemical compatibility, PPE, Good Engineering Practices, RCM, legal EHS requirements, BRSR, and more.

Language

English
Hindi
Marathi
Gujrati

Custom Section

  • Note of Appreciation, Asian Paints, Received for leading by example, working together, being open and honest in communication.
  • Recognition on the Spot, Asian Paints Limited, Received for Cycle time improvement of Emulsion Batches.
  • Employee of the Year, Asian Paints Limited, Received for Improvement in Cycle time in Acrylic Resins.
  • Safety Champion of the Year, Asian Paints Limited, Received for Safety Culture improvement from Reactive Safety Culture to Calculative Safety Culture in one year.

Timeline

Manager HSE, Compliance & Operations

Pidilite Industries Limited
02.2023 - Current

Sr. Manager Safety

DSM Firmenich- DRT Anthea
03.2022 - 02.2023

Manager EHS

Uflex Limited
09.2021 - 03.2022

Assistant Manager

Asian Paints Limited
01.2021 - 01.2022

Post Graduate Diploma - Industrial Safety

Central Labour Institute

Master's - chemistry

Allahabad University

PGDM - Operations

Similar Profiles

  • EMMANUEL AMEH JOSEPHEMMANUEL AMEH JOSEPH

    Compliance and HSE Manager at Broxburn BottlersCompliance and HSE Manager at Broxburn Bottlers

  • Jagdish ChaudharyJagdish Chaudhary

    <ul><li>Key Role: Heading the HSE & AI department and acting as a Senior Management Personnel (SMP)</li><li>Responsibilities:</li><li>Corporate HSE & AI Functions:</li><li>Developed and implemented IRM’s HSE & AI policy and management system.</li><li>Spearheaded leadership development and safety culture initiatives across all levels.</li><li>Facilitated internal and external HSE communications and corporate-level engagement programs.</li><li>Oversaw compliance for ERDMP certification, PCB consents, and environmental audits.</li><li>Led HSE training strategy including induction programs and annual training calendars.</li><li>Initiated and monitored HSE & AI performance improvement plans and audits.</li><li>Developed strategic safety KPIs, trend analysis, and corporate-level MIS reporting.</li><li>Managed safety tours, incident investigations, and safety reward programs.</li><li>Championed process safety, MOC, RCA reviews, and critical safety studies.</li><li>Ensured effective GA-level implementation of HSE policies and risk management.</li><li>Conducted safety campaigns, mock drills, and employee engagement activities.</li><li>Geographical Area (GA) Operations HSE & AI Oversight:</li><li>Engaged field teams and contractors for proactive HSE compliance and audits.</li><li>Reviewed and maintained Asset Integrity systems including HAZOP, QRA, and Risk Registers.</li><li>Participated in PNGRB, IMS audits and implemented corrective actions at GA level.</li><li>Facilitated incident reporting to authorities and supported root cause investigations.</li><li>Supported GA-level environmental and emergency preparedness programs.</li></ul> at IRM Energy Limited<ul><li>Key Role: Heading the HSE & AI department and acting as a Senior Management Personnel (SMP)</li><li>Responsibilities:</li><li>Corporate HSE & AI Functions:</li><li>Developed and implemented IRM’s HSE & AI policy and management system.</li><li>Spearheaded leadership development and safety culture initiatives across all levels.</li><li>Facilitated internal and external HSE communications and corporate-level engagement programs.</li><li>Oversaw compliance for ERDMP certification, PCB consents, and environmental audits.</li><li>Led HSE training strategy including induction programs and annual training calendars.</li><li>Initiated and monitored HSE & AI performance improvement plans and audits.</li><li>Developed strategic safety KPIs, trend analysis, and corporate-level MIS reporting.</li><li>Managed safety tours, incident investigations, and safety reward programs.</li><li>Championed process safety, MOC, RCA reviews, and critical safety studies.</li><li>Ensured effective GA-level implementation of HSE policies and risk management.</li><li>Conducted safety campaigns, mock drills, and employee engagement activities.</li><li>Geographical Area (GA) Operations HSE & AI Oversight:</li><li>Engaged field teams and contractors for proactive HSE compliance and audits.</li><li>Reviewed and maintained Asset Integrity systems including HAZOP, QRA, and Risk Registers.</li><li>Participated in PNGRB, IMS audits and implemented corrective actions at GA level.</li><li>Facilitated incident reporting to authorities and supported root cause investigations.</li><li>Supported GA-level environmental and emergency preparedness programs.</li></ul> at IRM Energy Limited

  • Gayathri KrishnanGayathri Krishnan

    Corporate HSE Executive Compliance at Malaysia Marine & Heavy EngineeringCorporate HSE Executive Compliance at Malaysia Marine & Heavy Engineering

  • Sebastian KoronkowskiSebastian Koronkowski

    HSE & Compliance Manager at PrincipleHSE & Compliance Manager at Principle

CREATE PROFILE
KALBE MUSTAFA