Prafulla Rabinarayan Puhan
Plastic Injection Molding Engineer and Plant operation
Vasai,MH
Summary
Experienced Having an individual performance above and beyond normal responsibility, Passionate in maintenance with 18+ years' experience, highly experience of 24+ years in Plastic Injection Molding process trouble shooting and trained people, experience of 14+ years in plant automation, expertise to increase profitability and 8+ years in best leadership quality.
Resourceful plant management leader with expertise in cost controls, lean manufacturing principles and employee training. Experienced Plant Manager adept at improving output, maximizing quality and boosting employee satisfaction with hands-on management style. Recognized as effective business manager and motivational leader. Successful manufacturing management career spanning 22 years. Hardworking and passionate job seeker with strong organizational skills eager to secure entry-level Plant Head position. Ready to help team achieve company goals.
Overview
24
24
years of professional experience
3
3
years of post-secondary education
1
1
Certificate
2
2
Languages
Work History
Plant Manager
Jay Precision Pharmaceutical pvt ltd
(A Manufacturer of Medical devices of CIPLA) Vasai Road, Maharashtra
05.2023 - Current
- Forecasted future production needs accurately, allowing for strategic decision-making regarding staffing levels, equipment investments, and inventory management.
- Reduced costs by eliminating materials waste and unnecessary labor hours.
- Boosted employee morale and productivity through effective leadership and motivational techniques.
- Mentored and developed staff members, promoting professional growth opportunities within the organization.
- Implemented useful inventory management and tracking systems to reduce costs and improve operations.
- Enhanced safety standards with implementation of comprehensive safety training initiatives for all employees.
- Reduced downtime for maintenance by establishing a proactive preventive maintenance program.
- Increased production efficiency by optimizing plant layout and implementing process improvements.
- Promoted collaborative work environment to motivate and engage staff to achieve company objectives.
- Managed direction and planning for plant with focus on optimization of daily functions, exceeding customer expectations, and achieving KPIs.
- Led, trained and coached plant staff to facilitate high levels of productivity and quality.
- Maximized plant safety through proactive strategies and well-structured training.
- Identified and resolved process and equipment issues to minimize production downtime.
- Analyzed incident reports to identify trends in workplace injuries or near-misses; implemented corrective actions accordingly.
- Monitored and evaluated plant performance to identify areas for improvement and take corrective measures.
- Created plant policies and procedures for safe and productive operations.
- Provided direction and leadership to all levels of employees and managers.
- Implemented quality control measures to reduce defect rates and enhance product quality consistently.
- Conducted thorough root cause analyses on production issues, identifying solutions for continuous improvement efforts.
- Negotiated favorable contracts with suppliers, securing cost savings on raw materials without sacrificing quality.
- Streamlined supply chain operations, reducing lead times and improving inventory management.
- Directed employees and related programs to maximize team productivity and facility output.
- Enhanced plant productivity by streamlining operational processes.
- Fostered culture of safety, significantly reducing workplace accidents.
- Negotiated with vendors for timely delivery of raw materials, preventing production delays.
- Developed training programs to upskill workforce and improve productivity.
- Coordinated with other departments to align production with customer requirements.
- Managed personnel by implementing company policies, procedures, work rules, and disciplinary action.
- Researched latest industry trends and technologies, boosting knowledge and understanding of industrial production.
- Planned operations to meet established schedules, factoring in order demands and business forecasts.
- Evaluated employee performance and provided feedback and training as needed.
Plant Head
Vform Technopack Pvt Ltd (manufacturer of Plastic molding products from Caps & Closures )
Sangaredy
08.2020 - 05.2023
- Created new training program with focus on staff safety, food safety and production quality to achieve reduced labor costs and tighter control points.
- Managed direction and planning for plant with focus on optimization of daily functions, exceeding customer expectations and achieving KPIs.
- Provided direction and leadership to all levels of employees and managers.
- Redesigned operational workflow processes to maximize efficiency.
- Leaded and participated in cross functional teams to achieve specific goals and objectives .
- Presented objectives and goals of plant to team in way that influences actions of team members.
- Maintained quality of product with robust inspections and assessment team.
- Looked after or monitored maintenance with help of maintenance team to improve equipment performance.
- Handled completely new Project ( New Plastic Industry Setup ), suitable machine selection, manpower hiring and trained them to make competent.
- Developed in area of Production management and engineering
- Prepared or Monitored capital expenditure budget for plant
- Understood labor laws including contact labor and ensure compliance.
Factory Manager
Jay Precision Products (I) Pvt Ltd (Manufacturer of plastics molding products from HASBRO)
Panvel, Rasayani
01.2017 - 08.2020
- Setup new automated or semi automated assembly line to get most output.
- Analyzed financial reports, assessed factory productivity and devised plans of action to build productive plant operations.
- Led productive, motivated and loyal manufacturing team and generated factory-wide customer focus and pride in workmanship.
- Delivered factory-level communications and tactical direction and drove achievement of quality, delivery, productivity and financial performance goals and objectives.
- Communicated factory operational needs, objectives and performance standards with senior management and earned full upper management support.
- Applied lean principles to improve workflow and quality and reduce waste.
- Evaluated Plant activity to take necessary action for Kaizen.
- Anticipated and addressed production problems, material shortages, equipment malfunctions and unavoidable delays.
- Evaluated production schedules and orders to arrange required materials and plan staffing needs.
- Oversaw hiring processes for permanent and temporary seasonal staff.
- Identified areas for business improvements and utilized client feedback to drive developments.
- Coordinated company projects and programs that supported manufacturing function.
- Estimated costs and set quality standards.
- Oversaw routine maintenance programs and scheduled service to keep equipment functioning at peak levels.
- Worked with senior leadership to complete under-budget management on complex issues.
- Collaborated with technical and administrative teams to develop and implement successful corrective plans.
- Implemented knowledge to provide product quality assurance and executed inventory maintenance, optimizing work time.
- Trained in and implemented emergency response procedures to protect team members and property.
- Managed personnel by implementing company policies, procedures, work rules and disciplinary action.
- Recognized low-cost suppliers and managed deliveries to cut downtime and save costs.
- Utilized proven problem-solving techniques to improve customer satisfaction and vendor relations.
Production and Maintenance Engineer
Jay Precision Products India Pvt Ltd (Manufacturer of plastics molding products from CIPLA &FERRERO)
Mumbai ,Mira road
05.2012 - 01.2017
- Organized and directed maintenance shutdowns and startups.
- Handled all type of Maintenance like Hydraulic/Pneumatic/Electric/PLC Programming.
- Dismantled defective machines and equipment like 3 Axis Robots /Chiller/Compressor/ Injection mounding machine / Centralized conveying system/ Printing machine/Ultrasonic welding machine and installed new or repaired parts.
- Developed plant to automation system to reduce human interference and manpower requirement.
- Actualized strategic plans and managed equipment, lifecycles and processes.
- Diagnosed and resolved machine operation variations and equipment problems.
- Developed process improvements to increase reliability and equipment performance.
- Cleaned and lubricated parts and attended PM to keep equipment operating at peak performance.
- Developed and maintained courteous and effective working relationships.
- Used critical thinking to break down problems, evaluate solutions and make decisions.
- Monitored company inventory to keep stock levels and databases updated.
- Received and processed stock into inventory management system.
- Worked with customers to understand needs and provide excellent service.
- Validated process parameter with machine and mold as per IQ/OQ/DQ/PQ
- Prepared document ,maintain and retain them for traceability purpose
Service Engineer
Shini Plastics &Technologies (I) Ltd (manufacturer of plastics auxiliary machine & equipment )
Maharashtra & Gujarat
05.2010 - 04.2012
- Traveled to different Plastic Industries like Plastic Injection molding plants, plastic extrusion plants and Blow molding Plants, find out actual requirement on auxiliary machinery side according to customer needs
- Installed compete auxiliary automation solutions like Robotic automation systems , Feeding with central conveying units, Dosing & Mixing units, Drying & Dehumidifying systems, Granulating & Recycling Units, Heating and Cooling Units, Hot Runner Systems for factory automation.
- Troubleshooted all type of Machines related to Hydraulics, Pneumatics, or Electrical.
- Worked cross-functionally within organization and external partners, integrators and vendors.
- Engaged in first-level support for customers requiring routine support and troubleshooting.
- Generated PLC program of Euro12 / 67 input / output signal for Robot interlocking with Injection molding machine on which such signals has not provided.
- Tested and checked performance of hardware and software programs.
- Educated prospects on product implementation and usage and answered technical and security questions.
- Completed partial or full dismantling of equipment to quickly repair or replace defective components and restore functionality.
Production and Maintenance Engineer
Harman Plastic Industries (Manufacturer of nail polish bottles & plastic caps)
Mumbai ,Vasai
05.2008 - 05.2010
- Worked frequently with mechanical and electrical systems to complete knowledgeable inspections and skilled repairs.
- Developed process improvements to increase reliability and equipment performance.
- Organized and directed maintenance shutdowns and startups.
- Dismantled defective machines and equipment and installed new or repaired parts.
- Attend daily and preventive maintenance of Injection molding machine / auxiliaries /utility /hot stamping machines /Compressors/chiller/MTC etc to get overall efficiency.
- Prepared daily production report as well as set injection mounding machine parameters
- Planned and forecasted labor hours for new processes.
Production Cum Maintenance Engineer
Elle Electrical Pvt. Ltd (Manufacture of plastic modular switches and boards)
Mumbai ,Goregaon
03.2003 - 02.2008
- Processed so many materials like- LDPE, HDPE, PP, ABS, HIPS, PS, PC, DERLIN, NYLON, CO POLYSTER, PET, ACCRYLIC, and TPR
- Developed team communications and information for meetings.
- Achieved daily target, report to manager about daily production achievement.
- Maintaining daily reports and retain them
- Assembled any type of Injection Molding Machine Units due to strong Technical Experience., manufacturer of electrical modular series
- Improved operations through consistent hard work and dedication.
- Identified issues, analyzed information and provided solutions to problems.
- Learned new skills and applied to daily tasks to improve efficiency and productivity.
Production Engineer
Plastics Export Zundert (I) Ltd (Manufacturer of Marico's superior & multi cavity caps)
Verna ,Goa
03.2001 - 02.2003
- Practiced lean principles, which led to improvements in workflow and quality and waste reduction.
- Supervised entire production process and prepared proper documentation for dispatch.
- Applied lean manufacturing processes to enhance quality, reliability or cost-effectiveness.
- Reported variance reports for production orders.
- Communicated with other team members to enhance process and performance.
- Performed root cause analysis and implemented corrective actions.
- Investigated and proposed corrective actions for quality issues.
- Learned Electrical and process trouble shooting for smooth handle of machine.
- Created engineering documentation for manufacturing processes, equipment specifications and change notices
Education
PGD - Plastics Processing & Technology
(CIPET)
Howrah 02.2001 - 07.2001
B.Sc - Bachelor in Science
Gopabandhu Science College
Athagarh ,Odissa 01.1997 - 01.2000
Visited To K - Show ( 2 Times )
Germany
DusseldrofSkills
Time management
Certification
1) Ms Office (Good Excel Skill), 2) Auto CAD, 3) PLC Programming on Crozet, 4) Making Electrical Drawing on PC Schematic software.
Timeline
Plant Manager
Jay Precision Pharmaceutical pvt ltd
05.2023 - Current
Plant Head
Vform Technopack Pvt Ltd (manufacturer of Plastic molding products from Caps & Closures )
08.2020 - 05.2023
Factory Manager
Jay Precision Products (I) Pvt Ltd (Manufacturer of plastics molding products from HASBRO)
01.2017 - 08.2020
Production and Maintenance Engineer
Jay Precision Products India Pvt Ltd (Manufacturer of plastics molding products from CIPLA &FERRERO)
05.2012 - 01.2017
Service Engineer
Shini Plastics &Technologies (I) Ltd (manufacturer of plastics auxiliary machine & equipment )
05.2010 - 04.2012
Production and Maintenance Engineer
Harman Plastic Industries (Manufacturer of nail polish bottles & plastic caps)
05.2008 - 05.2010
Production Cum Maintenance Engineer
Elle Electrical Pvt. Ltd (Manufacture of plastic modular switches and boards)
03.2003 - 02.2008
Production Engineer
Plastics Export Zundert (I) Ltd (Manufacturer of Marico's superior & multi cavity caps)
03.2001 - 02.2003
PGD - Plastics Processing & Technology
(CIPET)
02.2001 - 07.2001
B.Sc - Bachelor in Science
Gopabandhu Science College
01.1997 - 01.2000
Visited To K - Show ( 2 Times )
Germany
Reading spiritual books and preaching Bhagwat mahapurana
Reading Srimad Bhagawat geeta and Mahapuran and practice them for self realizations ,self motivated ,self guided and then preach to others .
Languages
English
Advanced (C1)
Marathi
Advanced (C1)
Hindi
Advanced (C1)
Odiya
Bilingual or Proficient (C2)
Reading spiritual books and preaching Bhagwat mahapurana
Reading Shrimad Bhagawat geeta and Mahapuran and practice them for self realizations ,self motivation for being self guided and then preach to others .
Interests
I am Very much intrested in automation and Challanging Maintenance work
Work Preference
Work Type
Full TimeWork Location
HybridImportant To Me
Work-life balanceCompany CultureHealthcare benefitsPersonal development programsPaid sick leaveCareer advancementWork Availability
monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
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