Summary
Skills
Work History
Accomplishments
Certfications
Education
Timeline
Generic
Manoj Prasad

Manoj Prasad

Head Of Manufacturing
Pune,MH

Summary

Manufacturing expert with over 26 years of rich experience in leading & managing the strategic and operational performance of the Production Department,ensuring the successful delivery of business strategy, Key Performance Indicators (KPIs) and objectives, adhering to regulatory compliance and achieving commercial success.

Skills

Strategic Planning/Leadership

undefined

Work History

Head of Quality Assurance & Control and Welding

Thermax Limited
Pune, Maharashtra
  • Exhibited leadership in managing end-to-end quality control
    functions of the organization; created & implemented Quality
    Management System
    that achieves quality & produces an
    output with zero defects
  • Implemented CA/PA, TQM, APQP, OPEX, A3, Poka-yoke, 5S,
    Lean, 8D, Why-Why analysis, process mapping, Kanban,

    and so on in manufacturing processes to enhance quality,
    productivity, and profitability
  • ASME and PED job execution.
    Experience of obtaining or renew an ASME Certificate of
    Authorization to use the ASME Certification Mark for the
    latest edition of the ASME Boiler and Pressure Vessel Code,
    Sections.
  • Gained international exposure by visiting various customers & suppliers across USA, Europe, Japan, China, Dubai, Malaysia, France, Germany, Nigeria and Taiwan
  • Excellence in developing supplier/vendor assessment
    systems,
    identifying areas of quality failures and taking steps to
    rectify the system-wide preventive & corrective actions to avoid
    the reoccurrences.
  • Ensured that quality strategies and processes are in place to
    meet business objectives and operational needs in terms of price,
    quality and delivery targets and which enables the company to
    function and compete effectively in the market and in a sustained
    manner
  • Recognized for introducing new processes, machinery and
    equipment as per international standards for exporting chillers
    and achieved the reduction in cost of poor quality
  • Proven capabilities in establishing Compliance & SOPs, QA
    processes, Quality plans, MRS & checklists
    and
    streamlining workflow & creating work environment to
    enhance productivity innovatively.
  • Acted as Subject matter expert (SME) in Corrosion analysis.

Head of Production & MED

Thermax Limited
Pune, Maharashtra
  • Instrumental in establishing manufacturing processes at Thermax China Plant,2009.
  • Contributed in bootstrapping of new ultra-modern manufacturing plant in Sri City, Andhra Pradesh,2019.
  • Skilled in managing planning, coordination and control of manufacturing processes.
  • Experienced in managing manufacturing processes and level of quality.
  • Managed production planning that meet production target, keeping in view the sales forecast.
  • Experienced in establishing and managing production control systems to ensure continuous production and lesser work-in-progress.
  • Implemented initiatives for controlling the negative variables during production which may affect the ultimate quality of product.
  • Expert in analyzing various production processes in detail and implementing the most effective and economical process.
  • Excuted inventory control to minimise overstocking and understocking, in turn minimising wastage of raw-material and delay in production process.
  • Experienced in setting up plant layouts and managing effecive utilisation of available resources at minimum operating cost.

Head of Sourcing and Materials

Thermax Limited
Pune, Maharashtra
  • Managed the company's supply portfolio ensuring transparency of spending.
  • Generated and implemented efficient sourcing and category management strategies.
  • Expert in analyzing and calculating costs of procurement and implement methods to decrease expenditure.
  • Invented negotiation strategies and secured profitable deals.
  • Optimized sourcing procedures to attain maximum efficiency.
  • Cooperated with stakeholders to guarantee agreement on terms and processes.
  • Researched and anticipated shifts in the negotiating power of suppliers.
  • Expert in performing cost and scenario analysis, and benchmarking.
  • Discovered and partnered with trustworthy vendors and suppliers.
  • Planed material movement through production cycle.
  • Managed policies, procedures and material control systems.
  • Developed and reviewed personnel to meet functional objectives.
  • Created purchase orders, solicit proposal bids and review goods requisitions.
  • Expert in analyzing price proposals and financial reports to identify reasonable prices.

Accomplishments

Recognized for:

  • Establishing Production and Quality Management system for new plant in China and India.
  • Increasing export from 64% to 75% by enhancing product quality.

Honored with:

  • Appreciation award for implementing QMS in Chinchwad and Sicily plant.
  • Innovation award for implementation automatic orbital welding for tube for export machines.
  • Quality Excellence Award for improving quality system & reducing customer complaints during 2018-19.
  • Operational Excellence Award for implementing corrocoat painting process ,rubber lining of headers and SR process for carbon steel tubes.
  • Award for executing non-standard PUF Insulation for export job.
  • Award Trophy for welding improvement project.

Enhanced:

  • Productivity by 20% by initiating process improvement.
  • Overall product welding quality & decreased leakage below five per machine (around 85% leak reduction).
  • Manufacturing quality by more than 30% by identifying.
    process deficiencies

Reduced:

  • Customer complaints by 47% by CAPA and Failure analysis.
  • Cost by 50% by implementing Tube Plate Cladding by weld over lay process.
  • Manufacturing cost by 10% by indigenization of components.
  • Purchase cost by 20% by vendor selection & development.
  • Non-conformances by 35% by coordinating with suppliers.
  • Got Product Certification for US & Europe market.
  • Managed Operational Excellence project for Cooling SBU and completed 100+ cases of site returned failure analysis.
  • Established CuNi, Titanium, Stainless Steel welding processes.
  • Successfully established quality standards for Heat Exchangers ERW and seamless tubes for supplier and in-house control; worked with local and global Tube Mills for improving the quality of tubes.
  • Received certificate of appreciation for:
    1. Performing smooth transition to the 2015 Edition of ISO
    9001Standards
    2. Contributing in improvement project “ Design & Manufacturing of
    Titanium Headers for Vapour Absorption Machine”

Certfications

  • Third Party Inspection Role & Scope by Arkey Conference Service Cell in September 2000.
  • LRQA certified Internal Quality Auditor Failure Analysis by ASM International in January 2004.
  • Attended seminar on Modern Trends in Chemical Analysis and Reporting by Vishwa Bharti Educational & Charitable Trust.
  • Educational Course on Corrosion Control Awareness by Ambala Sarabhai Foundation in September 2007.
  • Oracle University Course by Oracle in March 2007.
  • Management of industrial corrosion & Inspection Strategy by CATS Inc. in July 2008.

Education

Diploma in Mechanical Engineering -

Board Of Technical Examinations Maharashtra Board
Mumbai
06.1990 - 06.1994

Post Graduation in Business Management -

SPPU ( Pune University )
Pune
06.2011 - 06.2013

Timeline

Post Graduation in Business Management -

SPPU ( Pune University )
06.2011 - 06.2013

Diploma in Mechanical Engineering -

Board Of Technical Examinations Maharashtra Board
06.1990 - 06.1994

Head of Quality Assurance & Control and Welding

Thermax Limited

Head of Production & MED

Thermax Limited

Head of Sourcing and Materials

Thermax Limited
Manoj PrasadHead Of Manufacturing