Ligeesh Joseph
Cochin
Summary
Seasoned leader in technical and operational management with a proven track record at Synthite Industries, enhancing plant efficiencies and scaling projects. Expert in Plant Design and Team Management, I've led significant productivity improvements and achieved a notable 92% Machine Efficiency. Skilled in ISO standards and Lean Six Sigma, I excel in driving projects to fruition and mentoring teams for excellence.
Overview
23
23
years of professional experience
1
1
Certification
Work History
Assistant General Manager- Technical Services-NPD
Synthite Industries Private Limited
Kolenchery
07.2014 - Current
- Identify and implement process improvement projects to improve operation efficiencies
- Scale up of new projects from pilot to Plant level
- Commissioning of new Equipment
Assistant General Manager- Operations
Synthite Industries Private Limited
Kolenchery
04.2023 - 11.2023
- Heading Turmeric operations- P&L responsibility of Turmeric Business
- Annual planning of turmeric production, purchase and optimize cost
- Responsible for Plant Efficiency (OEE), Material Yields, Quality, Safety of the operation
- Responsible for Curcumin recovery, Solvent recovery and other operational expenses
- Manpower planning for smooth operation, Selection and building of team for operation
Senior Manager- Operations
Synthite Industries Private Limited
Kolenchery
08.2020 - 04.2023
- Project Leader for green field Project of New Turmeric Extraction and Purification Plants
- Design- build- commission 60T day turmeric processing plant (1 Billion INR investment), 120 T Cgilli plant- 1.5Billion Investment
- Responsible for designing the process to optimize the recovery
- Selection of equipment, Vendors, Recruiting people, Negotiations with suppliers etc
- Review project progress with team members
- Setting up of Systems and Automations
- Get the central Govt incentive under MOFPI scheme for food processing units
Management Representative(MR)
Synthite Industries Private Limited
Kolenchery
01.2018 - 01.2020
- Management Representative (MR) for ISO systems (IMS-ISO 9001, ISO 14001& ISO 45001), FSCC, BRC, FAMI QS, HALAL, KOSHER and USFDA for 4 manufacturing units
- Manage Customer audits and ensure the various requirements are met
- Heading TPM implementation (2014-2018) and Continuous Improvement activities in the Bio Ingredients Division of Synthite
- Monitor the performance of TPM pillars and align improvement projects to the Business goals through Policy deployment
- Develop systems and processes for optimum operations, track performance targets, responsible for Overall Equipment efficiency, Quality improvements, and Delivery efficiency improvements
- Identify organizational and cultural factors and develop strategies in overcoming 'Resistance to change'
- Develop training modules, Mentoring TPM leaders as change agents
Manager TPM
PepsiCo India Holdings Pvt Ltd
Patiala
09.2013 - 07.2014
- Drive the TPM pillar activities
- Lead Lean Six Sigma Projects
- Implement M&W (PepsiCo's) system from the initial phase to Stage 2 by developing strategies and training the team
- Drive productivity improvement projects, by monitoring/ guiding/coaching team leaders
- Conducting promotional events for selected productivity themes
- Analyze the various losses including time and material losses and prepare MIS report to management
- Evaluate employee skills and knowledge regularly, providing hands-on training and mentoring to individuals with lagging skills
Manager Production/Asst. Manager Manufacturing Excellence
PepsiCo India Holdings Pvt Ltd
Bharuch
10.2010 - 09.2013
- Leading and administering a team of 18 Engineers including 4 Assistant Managers, 1 Production Executive and 13 Production Officers
- Managing production lines consisting of: 600 BPM Glass, 300 BPM PET, 120 BPM PET Water & 200 BPM Glass Juice Lines
- Overseeing production operations, scheduling of production runs in alignment with supply chain requirements and monthly sales inventory plan, Plan Change overs, Maintenance and align all departments including sales
- Implementing plans with a view to ensure timely accomplishment of production targets within the cost parameters; contributing towards the yearly volume of 1.2 crore cases production
- Ensuring quality product delivery; coordinating for manpower management, supplies and up-time of equipment
- Cordinating with different departments including Shipping, Quality, Maintenance, HR and Purchase for smooth operations
- Setting and delivering Productivity, Yield, DMC cost, Labour Cost (VLC) targets
- Carrying out daily & weekly reviews and meetings along with Plant Head & Regional Technical Head (LPM)
- Responsibility for selection, coaching, feedback and development of plant personnel, safety of personnel, facilities and equipment, discipline in the work force
- Responsible for maintenance of line equipments & spares management
- Identifying improvement projects, getting approval for CAPEX and executing the same
- Installation and commissioning of new line equipments and capacity expansion projects
- Worked with Maintenance Team to maximize the machine uptime in the absence of Maintenance Coordinator for 3 months
Sr. Production Executive
Hindustan Unilever Lever Ltd
Pune
10.2005 - 10.2010
- Managing Shifts of 125 people and 60 m/c which forms 5 manufacturing lines
- Meet Productions targets and various Quality standards of different customer countries
- Handling IR issues in shifts and maintaining shop floor discipline, as Pune factory is one of highly IR sensitive factories of HUL, Participate in union negotiations
- Coordinating with extended supply chain to ensure all time availability of raw materials & packing materials in accordance with production plan to achieve maximum plan compliance
- Data collection & analysis; replicating various improvements from other factories
- Responsible for TPM sustenance in the factory
- Participating in accident, incident and near misses investigation
- Implementing in all elements of UQCSRM in full at production floor to ensure consistent tea quality
Production Officer
Hindustan Coca-Cola Beverages Pvt. Ltd
Ghaziabad
04.2004 - 10.2005
- Successfully managed 600 BPM Glass Line as well as 200 BPM PET Line and managed the team of one GRB line personnel
- Acted as Line Efficiency Improvement Team Leader for GRB and In-Charge of CO2 consumption for the total plant
- Achieved: ME of 92% & PE of 80% on YTD basis against the pre-existing 90% ME & 76% PE
- Concentrate Yield of 99.8% & Crown Yield of 99.65% on YTD basis
- CO2 Yield of 70% against the pre-existing of 56%
- Quality Measure of 95 (product) & 65 (packaging)
- Reduction in the daily glass breakage to 0.1%
- Conveyor lubricant usage to 14 paise/case against the pre-existing 16 paise/case
- Improved CO2 Yield and conducted bottle washer temperature trials to reduce bottle breakages
Trainee Engineer
PepsiCo India Holdings Pvt. Ltd
Palakkad
06.2002 - 03.2004
- Handling Shift production activities- Leading production operators and responsible for meeting shift production target
- Delivered record production of Aquafina for the plant in a shift in December, 2002 & Pepsi (500 ml) for the plant in a shift in April, 2003
- Successfully reduced machine downtime of bottle washer of glass returnable bottle line by 25% and blow power from 0.50 Kwh/CS to 0.44
- Performed trials to blow Aquafina PET bottles at low pressure & established the same at 30 bar against existing pressure of 35 bar
- Achieved successful running of 500 ml Pet bottle packs without bottom pads on SMI shrink wrapper
Education
MBA - General Management
Indian Institute Of Management Kozhikode
Kozhikode03.2020
B.Tech - Mechanical Engineering
Rajiv Gandhi Institute Of Technology (Govt)
Kottayam04.2001
Skills
- Production & Maintenance
- Project Execution and Management
- Plant Design
- Installation and Commissioning
- PLC Programming/ Automation
- Interviews & Recruitments
- Production Planning
- Team Management
- Productivity Improvement
- TPM-Awards- JIPM
- Lean Six Sigma
- Kaizen
- 5S
- ISO 9000
- ISO 22000
- ISO 14000
- ISO 18000
- ISO 50000
- BRC
- FAMI QS
Certification
- PREVENTIVE CONTROLS QUALIFIED INDIVIDUAL (PCQI)
- FSSC 22000 Lead Auditor (FSMS)
- ISO 9001 Quality Management System Lead Auditor
- ISO 22000 : 2018 FSMS Certification
- Influencing Skills & Leading Teams- Unilever
- TPM Facilitator Course-JIPM/Unilever
- Kaizen Leader Training- Lean Six Sigma- PepsiCo
- Next-stage manufacturing & TPM-JIPM
- Global expansion of the KARAKURI KAIZEN-in Japan
- Du-Pont Methodology of Safety
- BQT(Bottler Quality Training) Training of Pepsi
- DT5-Drive the 5- Workshop- Pepsi- Efficiency improvement Tool
- World Wide Training Programme on Bottling Equipments of Coca Cola
- First Time Manager Workshop-PepsiCo
- Collaborate to Win Workshop-PepsiCo
- Energy Management by Confederation of Indian Industry
Personal Information
Date of Birth: 09/03/80
Timeline
Assistant General Manager- Operations
Synthite Industries Private Limited
04.2023 - 11.2023
Senior Manager- Operations
Synthite Industries Private Limited
08.2020 - 04.2023
Management Representative(MR)
Synthite Industries Private Limited
01.2018 - 01.2020
Assistant General Manager- Technical Services-NPD
Synthite Industries Private Limited
07.2014 - Current
Manager TPM
PepsiCo India Holdings Pvt Ltd
09.2013 - 07.2014
Manager Production/Asst. Manager Manufacturing Excellence
PepsiCo India Holdings Pvt Ltd
10.2010 - 09.2013
Sr. Production Executive
Hindustan Unilever Lever Ltd
10.2005 - 10.2010
Production Officer
Hindustan Coca-Cola Beverages Pvt. Ltd
04.2004 - 10.2005
Trainee Engineer
PepsiCo India Holdings Pvt. Ltd
06.2002 - 03.2004
MBA - General Management
Indian Institute Of Management Kozhikode
B.Tech - Mechanical Engineering
Rajiv Gandhi Institute Of Technology (Govt)
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