NILESH V. MAHAJAN

• Lean Expertise: Implement lean principles and methodologies to optimize processes.
• Operational Excellence: Focus on improving efficiency, quality, and cost reduction.
• Strategic Leadership: Spearhead the digital transformation strategy for the site.
• Technology Integration: Oversee the integration of digital tools and technologies.
• Change Management: Drive cultural change and employee engagement in the transformation.
• Data Analytics: Utilize data-driven insights for decision-making and continuous improvement.
• Cross-functional Collaboration: Foster collaboration across departments and teams.
• Performance Metrics: Establish KPIs and performance measurement for progress tracking.
• Risk Management: Identify and mitigate risks associated with the transformation.
• Sustainability: Consider sustainability and environmental factors in operations.
• Regulatory Compliance: Ensure compliance with industry regulations and standards.
• Team Development: Build and develop a skilled team to support the transformation.
• Stakeholder Communication: Effectively communicate with senior management and stakeholders.
• Budget Management: Manage resources and budgets effectively for the transformation.
• Continuous Improvement: Promote a culture of continuous improvement and innovation.

Attainment:

• Successfully completed Tank-65, Tank-66 & Tank-67 project within planned time frame
• Ramping up of new tank and achieving production as per target achieved within one month of operation
• Recruitment and training of new manpower for tank done successfully
• Implemented new material handling system in line with Industry 4.0, automated guided vehicle for transportation of finished goods
• Qualification of all new equipment's and products of new tank as per international requirement.
• Best project award among all SCHOTT factories worldwide.
• Successfully completed project for new world class laboratory for analysis of glass.
• Established lean culture in organization.
• Successful implementation of 6S & TPM across the plant.
• Set schedules with clear understanding of coverage needs and employee abilities.
• Kept facilities clean and organized to present professional view to all visitors.
• Motivated, trained, and disciplined employees to maximize performance.
• Collaborated with other departments to establish productive and timely completion of projects.
• Developed and implemented policies and procedures to improve customer service and satisfaction.
• Recruited, hired, and trained initial personnel, working to establish key internal functions and outline scope of positions for new organization.
• Reduced operational risks while organizing data to forecast performance trends.
• Implemented innovative programs to increase employee loyalty and reduce turnover.

• Production planning & execution ensure maximum utilization of available resources.
• Maintain the norms of products & maintain overall control of operations
• Coordinating with other departments to achieve the targeted figures. Planning for Preventive Maintenance and General Maintenance to ensure proper up-keep of plant and machinery
• Monitoring of process, cost cutting and take corrective action
• Implementation of ISO 9001, 14000, 18000, EnMS 50001 & Manufacturing Excellence activities on shop floor.
• Ensure adherence to EHS Norms on shop floor and highlight unsafe conditions, unsafe acts
• Ensure proper storing of finished goods in ware house
• Ensure fulfilment of key tasks by subordinates
• Physical verification of stocks and variance analysis – Book v/s Actual
• Initiate efforts for waste minimization & yield improvement by optimizing process parameters
• Lead the team to deliver on schedule so that customer service targets are met.
• Prepare monthly production plan in coordination with marketing, schedule it and translate the same into optimized efficient supply process to meet the service objectives.
• Own the process ensuring compliance to all systems and EHS requirement.
• Drive the team to continuously improve upon its EHS performance and achieve high standards expected from shop floor. Facilitate imbibing the EHS culture in the plant.
• Monitor and implement planning schedules in a manner that dispatch accuracy targets of the plant are met.
• Maintain a high level of motivation at the site and drive the development of shop floor personnel and managing shop floor discipline.

Attainment:

• Packing cost reduced from Rs.1789/MT to Rs.1380/MT by changes in packing design
• Internal glass breakage reduced from 46.8MT/Month to 14.3MT/Month
• Handled plant without any loss during technicians strike
• Open glass dispatches increased from 1446MT/Month to 9145MT/Month
• Developed and implemented new Microsoft ERP system for process
• Driving Autonomous Maintenance activities throughout the plant
• Optimized contract manpower by time and motion analysis
• Reduced Manpower cost per ton for Dispatch by developing standard BOM.
• Standardization of various process parameters to achieve consistently yield above 90%
• Skill gap analysis of all team members, developing training programme & calendar and imparting training as per it and checking Training effectiveness
• Recommended and implemented successful strategies to maximize revenue.
• Identified cost improvement changes and cost savings plans to increase company savings.
• Implemented and developed operational standards, policies and procedures.

• Start-up of 550 TPD plant
• Achieved the target yield within six months of operation
• Handled the major breakdowns like, Glass leakage from furnace, Tin Bath upset
• Reassume the production after major tin bath upset within 45 days record time
• Solved the critical problem of bottom scratch on glass
• Trained all company and contract employees in respective area for operation
• Established standard for quality as per norms

• Completed JH step-3 activities on Manager Model Machine
• Developed systems for generating data from shop floor required as per JIPM standards
• Reduced the Setup and Changeover loss for MMM from 240 mins to 30 mins by performing various small improvements
• Reduced the start-up loss on MMM from 120 min to 15 min
• Reduced the overall length of the machine from 33Mtr to 20 Mtr by eliminating machines from line
• Achieved the TPM Kick off for factory and started plant wide implementation.

• Reduced the breakdown due to paper joint from 1.33 Hrs/Month to 0.625 Hrs/month
• Reduced the Dry waste due to broken boards from 0.25 % to 0.115%
• Board weight reduced from 9.7 kg/Sqm to 9.0 Kg/Sqm
• Completed FI project to reduce the calcinations burner downtime from 7.25 Hrs/month to 3.5 Hrs/month
• Implemented AM step 0 to 3 on mixer and Bundler.
• Decreased in-house production issues by establishing and coordinating sub-contracting and outsourcing requirements and processes.
• Created engineering documentation for manufacturing processes, equipment specifications and change notices.
• Supervised entire production process and prepared proper documentation for dispatch.
• Investigated and proposed corrective actions for quality issues.
• Reported variance reports for production orders.
• Performed root cause analysis and implemented corrective actions.
• Identified risk mitigation actions to reduce injuries, accidents and hazards in production environment.
• Communicated with other team members to enhance process and performance.
• Trained team on best practices to optimize production and improve quality.

Looking after the TPM activities of the company, Lead the company's Kobetsu Kaizen pillar under TPM activities and Worked as Production Engineer, Reporting to Production Manager

• Successfully established the Technical Training Center for the Training of all employees under TPM
• Launched a new Production Information Management System Software successfully, which facilitates the day-to-day monitoring of losses and OEE
• Developed systems for generating data from shop floor required as per JIPM standards
• Reduced the pack size changeover time on CEKA machine from 360min to 55mins by performing various small improvements (ECRS method)
• Successfully completed the JIPM audit for the Level 1 Award of TPM
• Looking after the production and maintenance of Detergent plant
• Well versed with the maintenance of process equipment's like Pumps, conveyors, Mixers Blunders & Utility area, FFS Machines, WRAPPING Machines
• Active participation in TPM activities and safety related activities
• Leaded the JH team to achieve the targets under TPM activities
• Communicated with other team members to enhance process and performance.

• Looking after production and maintenance activities and Reporting to Production Manager.