MANOJ KUMAR DWIVEDI
Kanpur
Summary
Seeking a senior leadership role as Unit Head with renowned companies, demanding strong exposure to manufacturing, operations, maintenance, plant engineering, project management, and administration.
Technically competent managerial talent with a career excellence of over 30 years in steering multiple technical domains in top-grade manufacturing organizations in the textile, food, and FMCG sectors. Proven capabilities in managing entire manufacturing operations, including production, maintenance, quality, and plant engineering, to optimize overall operational efficiency. Demonstrated professional strengths in executing challenging engineering projects within defined time and cost parameters. Strong practical exposure to productivity-enhancing techniques, viz., TPM, Kaizen, M&W, and DT-5 initiatives. Acknowledged team leader, trainer, and motivator with fine-tuned analytical, administrative, and troubleshooting skills. Superior verbal and written communication. Conversant with SAP R/3 PP and MM modules.
Overview
40
40
years of professional experience
Work History
Project Head (Green Field) / Plant Manager - AVP
Varun Beverages Limited
Barauni, Begusarai and Buxar
12.2020 - Current
- Heading the Mega Project of 800 Cr & post completion of project activities deploy as plant head for entire activities.
Plant Manager – AVP
Varun Beverages Limited
Chopanki, Bhiwadi
09.2018 - 01.2020
- Responsible for plant technical activities, Liasoning with govt officials & political leaders.
Project Head (Green Field) / Plant Manager - AVP
Varun Beverages Limited
Sandila, Hardoi
11.2016 - 10.2018
- Heading the Mega Project of 500 Cr & post completion of project work as plant head for entire activities.
Plant Manager – AVP
Varun Beverages Limited
Sathariya, Jaunpur
03.2015 - 01.2016
- Heading the 02 plant for entire activities.
General Manager – Manufacturing
PepsiCo India Holdings Pvt Ltd
Jainpur, Kanpur Dehat
04.2012 - 02.2015
- Managed entire manufacturing operations covering AOP Planning, operations budgets, production, quality, maintenance, Spares Management, Safety Compliance, new projects and liaison & administration.
- Conducted in house training sessions on 5S, TPM, including equipment specific training like Air compressor, boiler, refrigeration system, maintenance practices
Project Manager
PepsiCo International
10.2007 - 03.2012
- Core member of the PepsiCo Project Team at BU office at Gurgaon. Played key role in finalising requirements & execution for new projects following techno-Commercial discussion and negotiation meetings with the vendors.
- Contributing technical & managerial inputs in the areas of Maintenance, plant engineering, tooling, instrumentation, plant utilities, procurement and management of spares, etc.
- Providing creative inputs in multifunctional meetings to map areas for improvements and chart out action plans to implement initiatives.
- Identified new projects applying MEP, prepared detailed analytical project plan with cost estimates and ROI incidences. Facilitated multidisciplinary approvals justifying technical and commercial viability of the project.
- Periodically arranging training sessions for workforce and implementing operator egg timer modules to keep their skill levels up-to-date.
- Liaison with gov officials like pollution, electrical, fire dept and meet the compliance for smooth running of the project & plant operation.
- Achievements:
- Good techno commercial negotiation skill has resulted in huge savings in capexes.
- Planned & Executed various projects like Commissioning of HF line & New CSD PET Line starting from civil work up to the commissioning of all the Equipments well within the time lines, auto temp control of Pasteuriser through SCADA system.
- Computed total requirements of inputs for:
- Project Phase II of the Rs. 7 Crore- Slice HF Project 73 BPM including all civil work in 2007.
- Rs. 29 Crore - W/h, Lab Office & WTP Expansion projects & commissioning of New CSD PET line -300 BPM.
- Rs. 83 Crore – Planning & Commissioning of new 300 BPM CSD SS PET line & 200 BPM CSD PET MS line with all required utilities equipments. Expansion of ware house along with Racking system In Bazpur, Uttrakhand
- Rs 23 Crore – Commissioning of 300 BPM New HF RGB line with all the required utilities in Jainpur, Kanpur, Uttar Pradesh.
- Rs 45 Crore – Commissioning of 300 BPM new CSD PET line with all the required utilities & complete civil work of Co packer in Trichy, Tamilnadu.
Service Engineer / Production Engineer / Production Co-ordinator /Quality Control Manager
PepsiCo India Holdings Ltd
Jainpur Kanpur
04.1996 - 10.2007
- A fortune 500 company having extensive global operations with manufacturing units located across multiple international locations. In India, co.'s largest plant is located at Jainpur Kanpur UP.
- Joined Pepsi in 1996 as Service Engineer (MEM) & transferred to Plant in 1998 as production Engineer and promoted as Production Coordinator in March 2000 with responsibilities of managing independently GB, PET, Juice line and achieving the set production targets in a defined conversion cost.
- I have been promoted as Quality Control Manager in Oct.2006 with responsibilities of managing entire quality operation covering HACCP certification & we got HACCP certificate in 2007.
- Managed entire manufacturing operations covering AOP Planning, operations budgets, production, quality, maintenance, Spares Management, Safety Compliance, new projects and liaison & administration.
- Conducted in house training sessions on 5S, TPM, including equipment specific training like Air compressor, boiler, refrigeration system, maintenance practices
- Achievements:
- Generated high operational efficiency with judicious deployment of manpower, machines and material resources.
- Registered production of 21.8 Lakh cases in May’04 without any incident of major breakdown. This landmark production level earned top rank in PepsiCo India BU history.
- Implemented production efficiency improvement tool like DT5 on KHS line and increased line productivity from 70% to 81% in a span of 6 months
- Maximised uptime of machines with deft implementation of preventive/predictive maintenance.
- Implemented M&W 18 action planners and recorded marked improvement in plant KPMs Power/case, Fuel/case, KWH/ Ltr.
- Driven water recovery initiatives and reduced water consumption from 45 ltr/case to 10 ltr/case. Improved fuel efficiency by recovering heat from the Exhaust gases of the DG set and using the steam generated from HRU unit to preheat the feed water of boiler.
- Implemented Enercon Energy Monitoring System and achieved considerable reduction in power consumption from 0.47/case to 0.35 per case in 1 year.
- Deftly utilised MS Project 2000 in scheduling, monitoring and tracking of project work progress.
- Successfully commissioned DG synchronization & Juice line Expansion project to meet the market needs.
- Received Star Award for successfully commissioning of DG synchronization within time & budget & without hamper production.
- Executed Rainwater Harvesting project in the plant to minimise the water wastage.
Asstt .Manager
Prakati synthetics Ltd. (Division of LML fibres Ltd.)
Kanpur
02.1989 - 12.1996
- Company Overview: A large Polyester & Nylon yarn manufacturing unit.
- Independently managed the Texturising Machine & Electrical equipments with preventive maintenance practices. Implemented Autonomous Maintenance.
- Achieved substantial Power saving through Quality Circles. Formed SGA team and implemented energy conservation initiatives in utility area.
- Developed indigenous sources for several imported Spare Parts.
Supervisor (Electrical)
Lohia Machines Ltd.
Kanpur
08.1985 - 01.1989
- Company Overview: A large, Manufacturer of Textile machines.
- Independently handled the electrical department of 10 people looking after preventative maintenance of all the equipments & machines.
Education
Diploma - Electrical
Govt. Polytechnic
Kanpur, Uttar PradeshSkills
- Production management
- Overseeing production related tasks including planning, control and trouble shooting
- Setting up production targets and achieving the same within time and cost parameters
- Optimizing man & machine utilization to achieve pre set production targets
- Operations & Maintenance:
- Planning predictive & preventive maintenance schedules for equipments, conducting periodic checks to ensure performance of various equipments
- Identifying areas of obstruction/ breakdowns and take steps to rectify the equipments through application of trouble shooting tools (5 why analysis)
- Coordinating material/ spare parts planning related activities encompassing identification of vendors, requirement specification & offer evaluation
- Quality Control/Assurance:
- Ensuring adherence to quality standards, GMP, quality IQMS
- Identifying areas of quality failures and taking steps to rectify the system wide preventive and corrective actions to avoid the reoccurrences
- Practicing quality standards with key emphasis on improving quality and improvement opportunities
- Developing quality systems as per GMP, HACCP, Maintaining quality records
- Commercial Management
- Preparing the R&M budgets, new capex proposals in discussion with various departments for Plant operations as well as infrastructural developments
- Sourcing / Procurement
- Active participation in Vendor identification/ development
- Reviewing critical spare management and planning stock level accordingly
- Man Management :
- Leading/motivating teams ensuring their career development & positive contribution to the company
- Imparting training to various personnel's, thereby ensuring optimum performance
- Assuring for maximum utilization of resources such as Man, Material, Machine & Time
- Determining the manpower requirement in accordance with manpower rationalization and the production norms
- Safety / Health & Environmental Management System:
- Creating effective procedures for the preparation and implementation of programs within the area of industrial safety and the environment in plant
- Developing Emergency Plan; involved in the development of Safety Policies and Manuals
- Formulating & administering safety measures and risk assessments to prevent accident / incident, plant/property damage
- Project Management:
- Managing New & Expansion Projects Evaluating of project, present cost / benefits analysis at project decision points
- Spearheading project activities involving working out various requirements & monitoring overall project operations for ensuring timely completion
- Coordinating projects for the set up standards with accountability for strategic utilization & deployment of available resources to achieve organizational objectives
- Planning and finalizing the requirements and specifications in consultation with engineering and design consultants
- Erection & Commissioning:
- Ensuring completion of production process within the time & cost parameters and effective resource utilization to maximize the output
- Handling the installation and commissioning, as well as conducting tests and inspections to ensure the operational effectiveness of plant and utilities
- Conducting tests and trials of machines and equipment
Training
- SAP R/3 - Maintenance Module & Production planning training at Calcutta.
- Attended 04 days Project Management programme at IIM, Lucknow.
Timeline
Project Head (Green Field) / Plant Manager - AVP
Varun Beverages Limited
12.2020 - Current
Plant Manager – AVP
Varun Beverages Limited
09.2018 - 01.2020
Project Head (Green Field) / Plant Manager - AVP
Varun Beverages Limited
11.2016 - 10.2018
Plant Manager – AVP
Varun Beverages Limited
03.2015 - 01.2016
General Manager – Manufacturing
PepsiCo India Holdings Pvt Ltd
04.2012 - 02.2015
Project Manager
PepsiCo International
10.2007 - 03.2012
Service Engineer / Production Engineer / Production Co-ordinator /Quality Control Manager
PepsiCo India Holdings Ltd
04.1996 - 10.2007
Asstt .Manager
Prakati synthetics Ltd. (Division of LML fibres Ltd.)
02.1989 - 12.1996
Supervisor (Electrical)
Lohia Machines Ltd.
08.1985 - 01.1989
Diploma - Electrical
Govt. Polytechnic
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