Prashant D Sarode
Production manager
Vadodara
Summary
Experienced with team leadership, strategic planning, and operational management. Utilizes effective communication and organizational skills to drive project success. Track record of fostering productive work environments and achieving set goals.
Overview
25
25
years of professional experience
1
1
Certification
1
1
Language
Work History
Manager-Production
Chemco Plastic industries pvt. Ltd Vadodara, Gujarat
09.2019 - Current
- Company Overview: Manufacturer of PET Preforms one of the biggest supplier for Coca cola & Campa cola
- Developing production monitoring systems development method improvement & line balancing for a variety of jobs resulting in productivity improvement
- Troubleshooting of processing issues to achieve the quality standard for enhanced satisfaction of customer
- Maintain hygiene & safety of m/c & mold as well the plant area
- Scheduling and planning predictive, preventive and breakdown maintenance jobs with key Focus on spares availability and root cause analysis
- Preparing maintenance plans/schedules for reducing machinery downtime to minimum for Ensuring smooth production
- Budgeting the entire process operation and monitoring the maintenance operation to Ensure accomplishment of productivity targets.
- Implementing the mold changeover procedure and maintaining optimum time for Changeovers
- Improving documentation & records to each mold & H/R for study the changeovers frequency and according to that changing the worn parts before it get damages to avoid unnecessary process quality issues & breakdowns of plant operation
- PROCESS CONTROL
- MAINTENANCE CONTROL
- Managed and motivated employees to be productive and engaged in work.
- Accomplished multiple tasks within established timeframes.
- Maintained professional, organized, and safe environment for employees and patrons.
- Achieved departmental goals by developing and executing strategic plans and performance metrics.
- Improved safety procedures to create safe working conditions for workers.
- Developed a strong company culture focused on employee engagement, collaboration, and continuous learning opportunities.
- Evaluated employee performance and conveyed constructive feedback to improve skills.
Assistant Manager production
Parle International (Unit of Parle Agro Pvt. Ltd.)
06.2008 - 08.2019
- Company Overview: Manufacturer of PET bottle, Preforms, Juice
- Weekly maintenance schedule and follow daily check list.
- Preventive maintenance of mold, machine, chiller, loader, dryer, Dehumidifier.
- Ascertaining machine product utilization up to 95% and downtime of machines to a minimum.
- Monitoring molding activities and preparing daily production reports for the same.
- Preparation of ORM Data to meet operational targets fetching through the DPR.
- Raw material & packing materials requisition & optimization of its best utilizations.
- Trials of different materials and color master batch in coordination with customer.
- Attending customer complaints and resolving them in least possible time.
- Involved in cycle time & process optimization of various components to increase productivity.
- Gathering quality feedback from QC department about previous shift's production and taking steps to prevent reoccurrence in one's own shift.
- Maintaining specification of plastics molded components like visual inspection, checking physical dimensions and quality during process.
- Ensuring proper manpower requisition & deployment of workmen on machine as per right man For the right job principle.
- Sustaining 5S, safety & CGMP systems in plant; ensuring usage of machine guards during entire production process.
- Ensuring Proper Drying Parameters Given to respective Raw materials & Proper M/c parameters like mold, machine & Nozzle tip heats are applied to optimize Production & manufacturing quality requirements & recording process data & comparing as well with the standards as per machine/mold suppliers.
- Performing Scheduled, preventive & Breakdown Maintenance activity with other subordinates as per prescribed formats from Mold & machines manufacturer [Husky].
- Achieving Mold change planned in target time with tool room communications & minimizing the mold maintenance time also with Maintenance team.
- Ensuring that every machine runs on its best cycles in means of productivity & m/c performance as well.
- Educating co-workers about plant hygiene, Hand sanitization, hazards & food safety policies & coping with audit teams in the same.
- Generating daily material requisition slip and inward of finished goods.
- Monitoring molding activities and preparing daily reports for the same.
- Sustaining 5S & CGMP systems in plant; ensuring usage of machine guards during entire production process.
- Educating co-workers about plant hygiene, hazards & food safety policies & coping with audit teams in the same.
- Key Responsibility
Shift Incharge / Injection Molding
Legrand India Pvt. Ltd., Nasik
04.2006 - 05.2008
- Company Overview: Legrand is a global specialist in electrical and digital building infrastructure
- To carry out mold change on Machines.
- Responsible for SMED Concept.
- To trouble shoot quality problems.
- To maintain production & quality documents.
- Analysis of Breakdown time, achived cycle time & rejection.
- Implementation of 5S in Plant.
- To maintain good housekeeping.
- Material reconciliation.
- To train operators for operation of machine, mold change over activities etc.
- Machines Operated : Arburg 40, 120, L& T 230 T.
- Job responsibilities :
Shift Incharge
Parle International (Unit of Parle Agro Pvt. Ltd.)
08.2000 - 03.2006
- Company Overview: Manufacturer of PET bottle, Preforms, Juice
- M/C operation, trouble shooting, Quality maintaining, Mold change over, mold & Hot runner maintenance, Handling the shift
- Manpower distribution according to the production planning
- Achieve production targets both qualitatively as well as Quantitatively within given time.
- Operation & Maintenance of Dryer like piovan and plastic systems.
- Machines Operated : Canada made Husky XL300, Husky Hypet 300, Krauss Maffei 175, Arburg 420
- Machine Erection : Hypet 300 & Kraussmaffei 3200 CV
- Key Responsibilities
- Self-motivated, with a strong sense of personal responsibility.
- Proven ability to learn quickly and adapt to new situations.
- Worked well in a team setting, providing support and guidance.
- Passionate about learning and committed to continual improvement.
- Managed time efficiently in order to complete all tasks within deadlines.
- Assisted with day-to-day operations, working efficiently and productively with all team members.
- Worked flexible hours across night, weekend, and holiday shifts.
- Demonstrated respect, friendliness and willingness to help wherever needed.
- Strengthened communication skills through regular interactions with others.
- Participated in team projects, demonstrating an ability to work collaboratively and effectively.
Education
Post Graduate Diploma - Plastic Processing
Central Institute of Petrochemical Engr. & Tech. – Chennai (CIPET)
01.1999 - 2000.01
B.Sc. - Chemistry
North Maharashtra University Jalgaon
01.1996 - 1999.01
Skills
- Focusing on optimization of process parameters & maintain the optimum cycle time and initiating process improvements for achieving bottom line objectives and productivity targets
- Had knowledge about the calibration of husky m/c mold & coolpik and cooljet
- Hands on experience of injection cylinder, Mold stroke, clamp stroke resealing workalong with Husky team
- Perform Neckring Alignment, Mold halves alignment & Mold breathing inspection
- solve the m/c process & technical issues of the hot runner mold defects as well trouble shooting
- Focusing on optimization of process parameters & maintain the optimum cycle time and initiating process improvements for achieving bottom line objectives and productivity targets
Team leadership
Operations management
Decision-making
Performance management
Time management
Staff development
Customer service
Project management
Staff management
Relationship building
Documentation and reporting
Product management
Key performance indicators
Shift scheduling
Safety procedures
Data analysis
Work prioritization
Problem-solving abilities
Problem-solving
Positive attitude
Self motivation
Team building
Effective communication
Continuous improvement
Training and development
Certification
Successfully completed the certified course PET Process & Hot runner maintenanace from Krauss maffei & Husky at Parrle Agro Silvassa.
Professional SYNOPSIS
24 - years of experience in production & maintenance operations of the HUSKY PET preforms injection molding & HDPE cap moulding machines like Arburg m/c in FMCG industry. Presently working as a Production manager with Chemco Plastic industries pvt. Ltd Vadodara, Gujarat (ISO 900 & FSSC :22000 stadards), Extensive experience in maintenance, planning & controlling of injection molding operations. Demonstrated abilities in achieving cost savings across assignments. Improved Preform Yield from 90 % to 98 % & Mechanical efficiency of 88 % to 90 %, reduced rejection % from 1.2 % to 0.40 % and Effective communicator with excellent skills of strong analytical and problem solving.
ACCOUNTABILITY & PROVEN AREAS WITH EXPERTISE
- PERFORMING PRODUCTION & MAINTENANCE PLANNING
- Prepare work schedule and m/c maintenance and mold change over procedure
- Review Spares, materials and tools requirement
- Prepare work instruction, Monitor production operation
- Improve production & m/c efficiency / productivity
- Conduct production and maintenance meeting
- ENSURE PRODUCT QUALITY
- Prepare PET processing trouble shooting methods, Comply with maintenance & organization Production standards
- Maintain scrap at low level & execute the analyze of production rejection, Prepare statistical process technique
- Maintain standard time for mold change over & process
- MAINTAINING PLANT
- Ensure plant operation in good condition, Ensure plant and m/c & mold spares parts stock level, Maintain plant cleanliness, Prepare & maintaining report for Maintenance and production department
- Handful Experience on Machines like Husky LX 300, Kraussmaffei, SIPA, Arburg, Husky 225 & 400 HPP 4.0 machines etc along with cavitation from 24, 32, 40, 96, 128, 180 etc molds from Husky, SIPA, MHT, GDXL etc.
- Worked Auxiliary Equipments:
- Dryer : Piovan, & Plastic System
- Dehumidifier : Piovan, Plastic System, Eisbar
- Chiller (Screw Compressor ) : Green box from Husky ( 40 to 120 TR) & Prasad Kotch etc.
- Air Compressor (Screw Type): Kesar Make.
- Water cooling tower & pumps : Advance cooling tower.
Timeline
Manager-Production
Chemco Plastic industries pvt. Ltd Vadodara, Gujarat
09.2019 - Current
Assistant Manager production
Parle International (Unit of Parle Agro Pvt. Ltd.)
06.2008 - 08.2019
Shift Incharge / Injection Molding
Legrand India Pvt. Ltd., Nasik
04.2006 - 05.2008
Shift Incharge
Parle International (Unit of Parle Agro Pvt. Ltd.)
08.2000 - 03.2006
Post Graduate Diploma - Plastic Processing
Central Institute of Petrochemical Engr. & Tech. – Chennai (CIPET)
01.1999 - 2000.01
B.Sc. - Chemistry
North Maharashtra University Jalgaon
01.1996 - 1999.01
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