Nikhil Kurankar
Operations Head
Pune,MH
Summary
Dynamic Operations and Industrial Engineering Leader with over 15 years of experience, including 9 years as Operations/Plant Head in thermoplastics and biopolymers manufacturing. Expertise includes a wide range of industrial engineering tools such as capacity planning, time and motion studies, and lean methodologies, including 5S, Kaizen, and TPM, aimed at fostering operational excellence and a culture of continuous improvement. Proven record of successfully commissioning new production lines, optimizing plant layouts, enhancing throughput by up to 40%, and achieving a 15% reduction in production costs. Proficient in ensuring compliance with ISO 9001, IATF 16949, ISO 22000, and GMP standards while effectively leading cross-functional teams through global audits.
Overview
16
16
years of professional experience
4
4
Certifications
Work History
Head of Operations
SKYi FKuR Biopolymers Pvt. Ltd.
02.2020 - Current
- Directed end-to-end plant setup, civil works, equipment installation, commissioning, and regulatory approvals. Installing 280 MT per month production capacity on schedule and within budget.
- Production Optimization: Increased production throughput by 10% and drove scrap/rejection down to just 0.3% through targeted process optimization, changeover reduction, and real-time performance monitoring.
- Lean and Continuous Improvement. Applied 5S, Kaizen, and TPM to cut cycle times by 15% and realize $18K in annual savings.
- Food Safety Shop Floor & FSMS. Implemented ISO 22000 Food Safety Management System; designed a dedicated food safety zone with hygiene SOPs, GMP controls, and zonal segregation for food-grade polymer production.
- Quality and Compliances. Conducted regular FSMS and process audits, maintained 95%+ compliance in hygiene and safety inspections by external bodies, and zero non-conformances.
- Trained and mentored 8+ technicians on new processes, hygiene standards, and equipment operation, embedding a culture of continuous improvement and food safety vigilance.
- Inventory and Scheduling. Streamlined raw-material procurement, JIT pull systems, and production scheduling to align inventory levels with demand and minimize lead times.
- Integrated KPI Dashboard: Developed a dashboard that consolidates yield, energy consumption, scrap rates, maintenance schedules, quality metrics, and production planning data—streamlining all key processes, accelerating root-cause analysis, and enabling real-time, data-driven decision-making.
Head of Operations
SKYi Composites Pvt. Ltd.
02.2017 - Current
- Directed comprehensive operations across production, quality, and plant performance, managing an installed capacity of 350 MT/month (~4,200 MT PA) with high efficiency, compliance, and quality assurance.
- Managed Long Fiber Thermoplastics (LFT) manufacturing operations, ensuring optimal production processes, scrap reduction measures, stringent quality control, and effective team coordination.
- Lean Manufacturing implementation by introducing lean principles, including 5S and Kaizen methodologies, results in enhanced efficiency and significant waste reduction across operations.
- Production Planning and Resource Allocation. Developed real-time planning and scheduling dashboards to monitor orders and dispatches.
- Implemented TPM initiatives, leading to minimized equipment downtime, and improved machinery reliability.
- Process Optimization and Continuous Improvement. Led cross-functional teams to identify and resolve process bottlenecks, achieving a 20% increase in productivity and a 15% reduction in production cycle time, resulting in annual cost savings of around $20,000 per annum.
- Quality and Safety Compliance. Conducted regular audits to ensure adherence to safety regulations and quality standards, integrating LFT manufacturing processes into ISO 9001:2015 quality management systems, and achieving 95%+ audit compliance.
- Developed and delivered training programs on lean manufacturing principles, safety protocols, and equipment operation, fostering a culture of continuous improvement and safety awareness.
- Received accolades from senior management for leading the successful development and completion of high-profile projects in long carbon fiber and long cellulose fiber thermoplastics, in close collaboration with the R&D team to drive innovation and technical excellence.
- Supervised the installation, commissioning, and maintenance of new machinery and equipment, ensuring efficient production workflows, and minimal disruption.
- Conducted regular safety training sessions, implemented corrective actions based on audit findings, and achieved a zero-accident record by proactively addressing potential hazards.
Marketing Manager
Enerrgia SKYi Developers
01.2010 - 01.2017
- Boosted website traffic by 50%, generating approximately 2,400 additional leads per year, and ₹12 crore in the annual sales pipeline.
- Drove 25% growth in qualified leads via multi-channel campaigns, adding ₹5 Cr incremental revenue opportunity.
- Improved conversion rates by 30% through optimized landing pages, unlocking approximately ₹3 crore in realized revenue.
- Achieved top SEO rankings for 12 priority keywords, building a sustainable ₹1.8 Cr annual revenue pipeline.
- Optimized a $20K marketing budget, saving ₹5 lakh, and driving an extra ₹1–2 crore in revenue impact.
Education
Master of Business Administration - Marketing
Indira Institute of Management
Pune, India05-2010
Bachelor of Engineering - Mechanical Engineering
Gogte Institute of Technology
Belgaum, India06-2007
Skills
Continuous Improvement & Lean Practices
Accomplishments
- Food Safety Manufacturing: Established an ISO 22000-compliant production site with zonal segregation and hygiene protocols for biopolymer compounding.
- OEE & Process Control: Achieved OEE of 80% through predictive maintenance, KPI dashboards for real-time decision-making & Operational excellence initiatives.
- Cost & Productivity Improvements: Cut production costs by 15% and downtime by 25% by applying Lean, TPM, SMED methodologies & CI roadmap.
- Capacity Planning & Line Balancing: Increased throughput by 20% by redesigning line balance and workflow without CapEx investment.
- Inventory Management: Cut WIP inventory by 30% using JIT pull systems and Kanban, freeing up working capital. Monitoring nonmoving stocks and control inventory.
- Sustainability & recycling: Designed and installed a closed-loop water-recycling system, cutting freshwater use by 50%. Implemented waste-stream segregation, recycling of compound scrap and developed a low-cost product.
- 95%+ on-time delivery. Developed a real-time planning & scheduling dashboards to monitor orders and dispatches.
- Global Collaboration: Worked with international suppliers, external auditors, and customer audits to maintain 95%+ compliance across operations
- Commissioned a new extrusion line at SKYi FKuR Biopolymers, one of fully automated compostable biopolymer compounding unit in India.
Certification
Lean Management. (Credential ID -957928)
Timeline
Head of Operations
SKYi FKuR Biopolymers Pvt. Ltd.
02.2020 - Current
Head of Operations
SKYi Composites Pvt. Ltd.
02.2017 - Current
Marketing Manager
Enerrgia SKYi Developers
01.2010 - 01.2017
Master of Business Administration - Marketing
Indira Institute of Management
Bachelor of Engineering - Mechanical Engineering
Gogte Institute of Technology
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