Kalpesh Sharma

Continuous Improvement Initiatives

• Measuring the current Key Performance Indicators (KPIs) and establishing baseline data for all the plants, establishing the system for the measurement of the same.
• Setting the targets for the OEE and then capturing the actual figures of the same. Laying out the system for OEE improvement.
• Mentoring DMAIC – Yield Improvement Task force, Right First Time Task Force
• Leading Innovation and Automation at all sites through various vendors L&T, Shree durga trading for closed loop system
• Conducting Gage R&R for all the lines at all the plants. Reviewing the same.
• Mentoring and coaching team members on Know- How of Gage R&R and Lean principles
• Ensuring Plant MIS and inventory stocks to be competent as per JIT and Heijunka levels
• Compliance to Plant Balance Score Card (Safety, Quality, Complaints, Volume compliance, Reliability- OEE, Yield and Unit per labour hour)- target Finalisation, Target Vs Actual and circulation to it at Weekly, Monthly basis with Score comparison to Global level
• Process capability study done at filler for the improvement of Process sigma level in Tirupati Wellness.
• Validation of high Selling Herbalife product – Shakemate at Wellness unit by stabilization of operation procedures
• Manpower management of 110+ direct operators and 100+ casual manpower in 1 particular shift of achieving the day plan of PC 120 MT and KKR 100 MT a day, With Zero tolerance on safety and Quality KPI
• Handling IR issues and union handling at Channo unit and Bhubaneswar unit with 2 settlement compliance with minimum dip in the plant volumes
• Leading Q. Component- Q- RFT – Right first Time, Value stream mapping, Process capability, Lowering standard deviation, Process mapping and Procedure/ System development
• Leading Productivity development by monitoring Yield, wastage mapping, Kaizen, check sheet development, scheduled vs Produced and PM yield monitoring along with financial recovery if any.
• Executing two task forces at Tirupati Wellness for the improvement in PQCDSM category as project Mentor.

a. Yield Improvement Task force

b. RFT task force/ AQL defect improvement

• Ensuring Prerequisite – Good Manufacturing Practices to be placed during operations
• OEE target Finalization for NPM machinery at wellness and validating same with Global team
• Ensuring Lead management for the connectivity of raw materials to plant.
• Deploying Problem solving tool A3 in arresting the challenges of Bottle necks
• As team member contributing to the task forces of Leakage reduction, Cost of Non quality task force through FMEA tool.
• Ensuring compliance of FG checking via micro check and packing quality assessment for Final FG clearance
• Handling Plant manpower, shift KPI tasks, efficiency and efficacy meet out of Man, Machine, Material, with Zero tolerance on Quality and Safety
• Partnering with cross functional team members on different Plant KPI tasks (Zero defects, zero accidents, zero tolerance)
• Partnered with R&D for NPD validation execution on shopfloor.
• Site Expert trainer – Kurkure from Channo unit
• Active Member of JH pillar – HCCBPL and PepsiCo Kolkata unit, Cleared JH step 3
• HCCBPL – Learned control charts basics while handling BPQI and PCQI parameters.
• Partnered with R&D at multiple stages on preparing GOLD KURKURE samples for reference at India Region and abroad.
• Achieving multiple targets Potato - 83.3% , Oil - 96.6% Seasoning - 97.5% , Laminate - 99%.with FP waste 3%. Achieving approx. 10 Lakh positive MUV
• Ensure MTD volume compliance with inventory planning and week wise production compliance with optimization of inventory. Week planning with central planner and responsible for case attainment delivery.
• Working with twin screw extruders with new setup of gravimetric system in seasoning.
• Ensuring the IRA > 80% compliance with 44 RM variants and 64 variants.
• Calculating the yield and tracking the efficiencies of 20 costly RM items and capturing the loss in terms of INR.
• Ensure cost minimization of the site and inventory management of 44 RMs and optimization of normal, & Virat laminates.
• Coordination with DFM management for efficiency validation, negotiation, targets and OPTICAL Sorter projects, commissioned complete PC line with Material balance validation along with 5S, TPM vertical setup with 4Sigma.