Summary
Overview
Work History
Education
Skills
Accomplishments
Awards
Certification
Languages
Timeline
Generic

NAGA BHUSHANAM K

Process & Technology Leader - Solar Glass Manufacturing
Machilipatnam

Summary

  • With 14+ years of experience in glass manufacturing, hot & cold end projects , quality & process engineering in the glass process industries, and a completed Masters in Ceramic/Glass Technology from the Indian Institute of Technology (IIT-BHU) - Varanasi, Offer a wealth of expertise.
  • Have a proven record of multitasking and leadership in company-level projects, prioritizing productivity , cost, and quality improvement across various industry processes.

Overview

16
16
years of professional experience
7
7
years of post-secondary education
10
10
Certifications

Work History

Process Technology Leader- Hot End & Cold End

Borosil Renewables Ltd
Bharuch
4 2023 - Current
  • Leading and executing a wide range of hot-end and cold process optimization, quality improvement, cost-saving, and productivity enhancement projects
  • Providing essential support to Production Function through data analysis, quality improvement, and standard operating procedure (SOP) development
  • Spearheading SIX Sigma, POKA- YOKE, KAIZEN, and Visual Management initiatives to optimize processes and drive bottom-line improvement.
  • Analyze hot end and cold end processes to identify bottlenecks, inefficiencies, and areas for improvement.
  • Develop and implement process improvement strategies to optimize productivity and product quality.
  • Implement new technologies and methodologies to enhance processes.
  • Regularly assess process performance and report findings to management and relevant stakeholders.
  • Identify trends and patterns to make data-driven decisions for continuous improvement.
  • Ensure that glass produced meets required quality standards and specifications.
  • Collaborate with Quality Control team to conduct regular quality checks and inspections.
  • Implement corrective actions to address any deviations or defects in production process.
  • Set performance goals and expectations for team members.
  • Work closely with Maintenance team to ensure optimal equipment performance and reliability.

Team Leader- Operations (Batch Plant & Furnace)

Saint-Gobain India Private Limited
Bhiwadi
07.2022 - 04.2023
  • Prioritize and enforce strong safety culture within team, adhering to all safety protocols and regulations.
  • Conduct regular safety briefings, identify potential hazards, and implement corrective actions to prevent accidents and incidents.
  • Smoothly handling of 925 TPD Glass melting continuous Furnace.
  • Lead and supervise the daily operations of the Batch Plant & Furnace, ensuring efficient and safe production processes.
  • Monitor quality of raw materials, and intermediate batches to maintain high-quality standards.
  • Collaborate with Quality team to address any quality issues and implement corrective measure.
  • Ensure proper maintenance of Batch Plant & Furnace equipment to prevent breakdowns and downtime.
  • Schedule regular inspections and coordinate with maintenance team for timely repairs and servicing.
  • Continuously analyze production processes and identify opportunities for improvement in efficiency, productivity, and cost-effectiveness.
  • Implement process enhancements and best practices to optimize operations
  • Provide guidance and support to team members, fostering a positive and motivated work environment.
  • Conduct performance evaluations, set performance goals, and identify training needs to enhance skills of team.
  • Prepare and submit regular reports on production output, equipment performance, and team performance to management.

Hot End Leader -Process & Technology

Binani 3B-the fibreglass company
Goa
08.2014 - 11.2021
  • Promotes and get safe environment in department.
  • Defining process specifications of Batch Plant, Furnace, Bushings and HVAC process & equipment. Keeping track of all changes and related reasons.
  • Leads laboratory measurements of raw materials. Issue suppliers specifications to SC department.
  • Analysis and improvement in Glass refining process through Glass Seed Analysis.
  • Development of new vendors and reduce cost of incoming raw materials.
  • Performed field study for identification & reduction of various glass fibre production failures.
  • Proposes possible product or process specifications changes to better meet customer needs or decrease production costs.
  • Development of Furnace modeling with help of Global team.
  • Use of Structured Problem Solving Methodology to resolve routine as well as chronic issues.
  • Leading of Cross-functional, continuous improvement and Six Sigma projects for Bottom Line Improvements.
  • Handling of special projects in-line with business objectives and Global Strategies.
  • Development of team by mentoring & guiding them in problem-solving & data driven approach.
  • Development of cross function relationships.

Engineer - Reach & Development

Bhanu Ceraglaze Pvt Ltd. Hyderabad
Hyderabad
11.2009 - 05.2012
  • Improve quality of existing products like Bonding Frit, Tiles Frit and Ceramic Glaze Frit, Process Modifications, Product development, Batch time reduction & Improvement of sales, Field Visits for Analysis of customer complaints

In Plant Trainee

RAK Ceramics Pvt Ltd
Samarlakota
12.2008 - 06.2009
  • Testing and Manufacturing Process of Glazed and Vitrified Tiles

In Plant Trainee

Vesuvius India Ltd
Vizag
06.2008 - 11.2008
  • Testing and Manufacturing of Monolithic Refractories

Education

Master of Technology - Ceramic / Glass Technology

Indian Institute of Technology (BHU)
Varanasi, India
07.2012 - 08.2014

Bachelor of Technology - Ceramic / Glass Technology

Indian Institute of Ceramics
Kolkata, India
08.2010 - 05.2012

Diploma - Ceramic Engineering

Government Institute of Ceramic Technology
Gudur, India
07.2006 - 11.2009

Skills

Project Management

Accomplishments

@ Borosil Renewables Limited:

  • Enhanced glass pull-to-packing efficiency by 2.5 %, saving 35 MINR by implementing continuous improvement initiatives to reduce defects (stones and blisters) and minimize losses.
  • Implemented combustion optimization strategies, achieving a 3% reduction in energy consumption, and yielding savings of 6 MINR.
  • Attained a 1.2% reduction in cold end defects, resulting in savings of 62 MINR.
  • Successfully executed Standard Operating Procedures (SOPs) for the cold end process.
  • Actively contributed to the production & quality team by facilitating process optimization initiatives in both cold and hot end areas, as well as spearheading projects aimed at enhancing cost savings,productivity & product quality.
  • Played a pivotal role in training and mentoring new graduate engineer trainees (GETs) while establishing and nurturing the process department.


@ Saint-Gobain India Private Limited:

  • Improved glass efficiency by 1% through the successful execution of various continuous improvement projects,resulting in enhanced production output and cost savings.
  • Led efforts to improve energy efficiency and sustainability in the glass manufacturing process, resulting in a 20% reduction in specific heat consumption.
  • Spearheaded initiatives that led to a significant 20% reduction in Batch plant spillage generation, streamlining operations, and minimizing waste.


@ Binani 3B-the fibreglass company:

  • Improvement of glass fibre forming process efficiency by 3.5% leading to savings of 50 MINR through various continuous improvement projects.
  • Collaborated with the Global team in the design and development of the glass fibre forming process to enhance the pull by 20%.
  • Reduction in fibre-forming breaks by 30%, improving process efficiency by 2%, saving 20 MINR.
  • Reduction of Glass fibre scrap generation by 4% leading to savings of 20 MINR
  • Part of the Batch time reduction project, to improve batch time by 20%, saving 10 MINR.
  • Part of the Lean Six Sigma Green Belt project, to improve fibre conversation efficiency by 2%, saving 20 MINR.
  • Reduced specific heat consumption of glass by 130 kcal/kg, saving 3 MINR.
  • Development of sample measurement process for product quality improvement, saving 3 MINR.
  • Reduced batch feed variation by 80% & achieved homogeneity in glass composition.
  • Improved product inspection & corrective actions by standardization.
  • Implemented the Artificial intelligence (AI) software, in Goa plant, for data storage and analysis.


@ Bhanu Cerglaze Private Limited:

  • Increase in sales by 10% with new product introduction & development.
  • Increase in sales by 25% with product quality improvement in ceramic frits.
  • Reduction in energy consumption by 1010 kcal/kg saving 6 MINR.
  • Standardization of tools for testing various products for quality improvements.

Awards

  • Received Gold Trophy in KAIZEN Competition arranged by QCFI, Mumbai Chapter in Sept 18
  • Received Silver Trophy in Essay writing Competition arranged by QCFI, Mumbai Chapter in June 21
  • Qualified the State Level Entrance Exam (ECET) conducted by State Technical Board in 2010 and Secured 4th rank in state level.
  • Bagged Certificate from Govt. Institute of Ceramic Technology for achieving Top position for the batch During Diploma in Ceramics.
  • Qualified National Level Graduate Aptitude Test Examination (GATE) conducted by IIT’s in 2012 and Secured All India Rank-81.
  • Receiving MHRD Scholarship for the year 2012-14
  • Awarded Letter of Appreciation from Plant President for successful completion of cold repair project.
  • Awarded Letter of Appreciation from Global Director (Operations) for successful completion of Lean Six Sigma Green Belt project and provided a saving of 27 MINR.
  • Awarded certificate of Appreciation from the Plant Director for successful completion of POKAYOKE & KAIZEN projects.
  • Recognized by the Managing Director for successfully completing the Clear to Green transition and achieving the highest efficiency (Yield) in the Bhiwadi float glass furnace.

Certification

Lean Six Sigma Green Belt & Minitab, MoreSteam University (USA), 2418-000695

Languages

Telugu
Bilingual or Proficient (C2)
Hindi
Bilingual or Proficient (C2)
English
Bilingual or Proficient (C2)

Timeline

Team Leader- Operations (Batch Plant & Furnace)

Saint-Gobain India Private Limited
07.2022 - 04.2023

Hot End Leader -Process & Technology

Binani 3B-the fibreglass company
08.2014 - 11.2021

Master of Technology - Ceramic / Glass Technology

Indian Institute of Technology (BHU)
07.2012 - 08.2014

Bachelor of Technology - Ceramic / Glass Technology

Indian Institute of Ceramics
08.2010 - 05.2012

Engineer - Reach & Development

Bhanu Ceraglaze Pvt Ltd. Hyderabad
11.2009 - 05.2012

In Plant Trainee

RAK Ceramics Pvt Ltd
12.2008 - 06.2009

In Plant Trainee

Vesuvius India Ltd
06.2008 - 11.2008

Diploma - Ceramic Engineering

Government Institute of Ceramic Technology
07.2006 - 11.2009

Process Technology Leader- Hot End & Cold End

Borosil Renewables Ltd
4 2023 - Current
Lean Six Sigma Green Belt & Minitab, MoreSteam University (USA), 2418-000695

Member of the Indian Institute of Ceramics Association

Undergone Lean Six Sigma Green Belt Training at Battice, Belgium by PWC 2019.

Attended Training for Glass technology by CelSian Glass & Solar BV at Brussels, Belgium in 2018-2019.

Undergone Minitab essentials training at Pune by Qsutra 2017.

Internal Auditor for Energy Management System-ISO 50001-2018

Internal Auditor for Quality Management System- ISO 9001-2015

Internal Auditor for Environment Management System- ISO 14001-2015

Internal Auditor for Occupational Health and Safety Management Systems-BS OHSAS 45001-2018.

Undergone leadership development program by COREREALTIONS, Belgium, Europe in 2018-2019.

NAGA BHUSHANAM KProcess & Technology Leader - Solar Glass Manufacturing