Pavan Kumar A R

Led the transformation of a traditional kitchen setup into a streamlined factory operation by implementing structured QA/QC systems and defining factory-standard workflows in collaboration with the Quality Assurance team.

My responsibilities:

• Planned and executed daily and weekly production activities to meet operational targets.
• Developed and implemented standardized systems and processes to streamline production operations.
• Managed weekly manpower planning based on production forecasts, ensuring optimal resource utilization.
• Identified and onboarded new vendors to fulfill production requirements in the absence of a procurement manager.
• Handled production and canteen costing, with a focus on cost reduction and sustainability initiatives.
• Achieved a 40% increase in production output by identifying and eliminating repetitive, time-consuming, and non-value-adding steps—without additional resources, using the same setup as the previous operation.

Operated in a fast-paced environment, consistently delivering results despite limited resources, and dynamic, on-the-spot challenges.

• Actively responded to personnel shortage in the production area by assuming position of a production executive. Mentored and guided 4 new team members, facilitating their seamless transition into full-time roles as productive executives.
• Participated in an End of Line automation project at Rice Meal Plant, successfully validating the equipment with cross-functional team members. Resulted in a reduction of 6 workforce positions, significantly improving productivity.
• Validated and improved performance of equipment installed for PLI project.
• Monitored quality control procedures to ensure finished products met standards.
• Implemented daily safety talks between employees and executed safety projects resulting in decreased shop-floor incidents.
• Managed day-to-day operations at the facility ensuring smooth flow of activities throughout the shift. (RM to FG)

• Supported the implementation of Planned Maintenance and aided in the development of Autonomous Maintenance in TMP Project.
• Coordinated procurement of parts/tools for preventive maintenance and Autonomous Maintenance by effectively communicating with suppliers and purchase team.
• Designed and implemented a comprehensive set of 120 training materials for operators.
• Optimized operator performance by simplifying regular maintenance operations under AM, resulting in a reduction of shift's breakdown registration from 20 to 8 complaints.
• Assumed primary technical assistance role for factory digitization project during temporary postponement of TPM due to COVID-19. Additionally, executed equipment procurement and installation for data recovery digitization.
• Utilized networking skills to develop relationships with local engineering vendors, enabling expedited acquisition of spares during machine breakdowns on shift. (As a plan B)
• Generated monthly TPM progress reports using Excel and created visually engaging presentations using PowerPoint for follow-up. meetings.

• Successfully contributed to the End of Line automation project in Masala Division, leading to a decrease in manpower requirements by 5 positions and monthly savings totaling 2.5 lakhs. Successfully assisted in validating SCADA-operated processes, resulting in meeting the targeted production of 15 tons per shift.
• Contributed to stock audits by reconciling inventory during scheduled annual, quarterly, and monthly events.
• Executed various shop floor developmental initiatives encompassing basic GMP/GHP/5S/Safety/Quality protocols for more than 30 projects.
• Consolidated and streamlined 14 daily/monthly reports into 4 reports, resulting in significant time savings
• Oversaw the performance and productivity of a large workforce during shifts.
• Regularly planned material and manpower on a weekly basis.

• Led successful initiatives to reduce costs through engineering projects, enhance vendor-supplied fresh raw material quality in the Quality department, and improve productivity through increased overall equipment effectiveness (OEE) within a 2-month period.
• Implemented requirement-based registrations for new vendors, facilitating project implementations.