Nithin Bade

CapEx Projects:

• Leading unit expansion projects – lines expansion, dry goods expansion, FG goods expansion, blending capacity tanks expansion projects, IIOT implementation for OEE, productivity, energy, and water management, CMMS implementation, and admin building expansion.
• Leading NPDs' execution at the site.

Maintenance:

• Asset care lead for implementing the manufacturing excellence pillars' requirements.
• Ensuring entire plant preventive maintenance, corrective maintenance by work order/job card execution process, and spares management.
• Managing the entire R&M budget.
• Leading the BD loss reductions.

Operations:

• Leading OEE and productivity improvement projects to improve unit operational costs.
• Leading energy and water savings initiatives for sustainable operations to reduce wastages.
• Leading quality initiatives for improving quality in production lines.
• Ensuring safety requirements are fulfilled in the unit, as per the guidelines for a safe work environment.
• LOTO Manager for the site.

CapEx Projects :

• I have led multiple expansion capex projects from proposal, budgeting, planning, scheduling, execution, to capitalizing the assets within the stipulated resources, timelines, budget allocations, and ensuring cash flows timely. Mentioning a few below:

1. Shuttle racking – Increased 50% storage capacity.

2. Bottling hall entire new line installations, replacement of monobloc fillers to unibloc machines, new rinser installations, and lab equipment upgrades.

3. IIoT implementation for OEE, energy, and water monitoring.

4. Overhead modular conveyor for OSC shifting from infeed to packing area of 45 m, with a 3 90-degree bend design.

5. Telescopic conveyors were implemented across Pan India for unloading and loading activities, helping to improve productivity.

6. Multitrack installation to improve OEE from the existing line.

7. 300 kW capacity solar panel implementation.

8. Water-saving initiatives, like increasing the water recovery rate.

9. Reducing the blend batch preparation time up to a 60% reduction in time.

10. New admin building renovations.

11. Caustic hot water, hot water, and DM water market bottle rinser – two machines implementation.

12. Engineering storage racks system.

Maintenance:

• Developed all asset care requirements at the site from budgeting the R&M budget, planning, scheduling, and execution by leading a team of a maintenance planner, a mechanical engineer, and a maintenance team of six members.

1. Preventive maintenance strategy for 300,000 volume units, which runs an average of 28 days per month. Maintained 90% plus adherence.

2. Corrective maintenance strategy – maintenance request form, job card, spares availability, and manpower resources allocation. Maintained 90% plus adherence.

3. Implemented the autonomous maintenance concepts at the site by training the production team, operators, and maintenance, which helped improve OEE.

4. Break down loss reduction by 60%.

5. Ensured that root causes were prepared using problem-solving tools.

6. Maintained machine availability by 85%.

7. Spares procuring and managing the availability at all times.

8. Managed the yearly R&M budget without exceeding the allocated budget to maintain the operations cost.

Operations :

• Improved OEE of the plant by 13% through multiple initiatives.
• Improved productivity by 23%, helping reduce operational costs.
• Managed R&M budget without exceeding the allocated budget.
• Reduced plant power consumption by 22%.
• Reduced water wastage by 12%.
• Kaizen implementations.
• Supported production planning and execution by meeting adherence to market demand.
• Ensured food safety standards.
• Led cross-functional teams to implement process improvements, enhancing operational efficiency and reducing project completion time significantly.

Manufacturing excellence :

• Lead the entire manufacturing excellence at the site by supporting unit pillar leads and implementing Asset Care, Engineering & Projects, and Energy Pillar as the pillar lead.
• Lead the strategic projects, such as OEE improvement, productivity improvement, RFT improvement, and water consumption reduction.
• Ensured on Gemba audits, 5S audits, energy audits, and meeting cadence.

Safety:

• As a dedicated safety officer for the site, I lead all the safety requirements.

1. Monitored unsafe conditions, unsafe acts, near misses, and first aid reporting and closure status.

2. Lead fire and electrical safety audits of the plant.

3. LOTO Manager for the site.

4. Implemented machinery safety requirements.

5. Pressure vessel testing requirements as per local authority guidelines.

• Production planning & Execution.
• Managed 300 plus work force for ensuring production activities.
• Executed the maintenance activities for smooth production.
• Trained operators & supervisors for capability improvement.
• Reduced the process wastages.
• Implemented multiple kaizens and projects.
• Proposed & implemented Capex projects for improved throughput.

• Have executed projects like Electrical Safety, Machine guarding, SLD of site, implementation of best practices.

• Internship on over all Thermal Power Generation Concept led by Divisional Engineer of the Unit.