RAHUL KUMAR
Plant Head / Plant Manager
Muzaffarnagar
Summary
Passionate about technology innovation and continuous improvement, overseeing all manufacturing activities within the plant including Production, QC, HR & Admin, Store & Purchase, Maintenance, Account & Finance, Logistic & SCM. Experienced in handling brownfield projects to enhance efficiency, utilization, and quality while reducing manufacturing costs and environmental impacts. Implementing strong Hi management practices and ensuring compliance with health, safety, and environmental standards. International exposure from collaborating with countries like South Africa & Israel for Lean manufacturing training. Driven to reach the zenith of the organization hierarchy through continuous self-development and critical technology experience.
Overview
23
23
years of professional experience
2002
2002
years of post-secondary education
4
4
Certifications
Work History
Plant Head
BirlaNu Limited
01.2024 - Current
- Company Overview: BirlaNu Limited, formerly known as HIL Limited, is a building materials company and a part of the CK Birla Group. The company specializes in manufacturing and distributing a wide range of building solutions, including roofing, construction chemicals, Pipes & fittings and other materials. BirlaNu operates under various brands such as Charminar, Birla Aerocon, and Parador.
- I oversee complete manufacturing activities of the plant i.e., Production, QC, HR & Admin, Store & Purchase, Maintenance, Account & Finance, Logistic & SCM etc.
- I am passionate about technology innovation and continuous improvement.
- I have also handled brownfield projects, enhancing efficiency, utilization, and quality, while reducing manufacturing costs and environmental impacts.
- I have also implemented good Hi management practices and ensured compliance with health, safety, and environmental standards.
- I have gained international exposure and knowledge from visiting and collaborating with various countries, such as South Africa & Israel also for Lean manufacturing training.
- Responsible for overseeing all aspects of the production facility, ensuring safety, quality, and efficiency.
- Also responsible for planning, quality control, maintenance, inventory management, and team leadership.
- To focus on cost reduction, process improvement, and adherence to safety and environmental regulations.
- Planning, organizing, and directing all production activities to meet output targets and deadlines, ensuring efficient use of resources and minimizing downtime.
- Implementing and maintaining quality standards throughout the production process, including raw material inspection, in-process quality checks, and final product inspection.
- Ensuring a safe working environment by enforcing safety procedures, conducting regular safety checks, and maintaining compliance with all relevant regulations.
- Managing raw materials, finished goods, and other supplies, ensuring optimal stock levels and coordinating with the supply chain for timely delivery.
- Recruiting, training, and supervising plant personnel, fostering a positive and productive work environment, and addressing any employee-related issues.
- Identifying areas for process optimization, implementing lean manufacturing principles, and driving continuous improvement initiatives to enhance efficiency and reduce costs.
- Monitoring and controlling operational costs, developing and managing budgets, and identifying cost-saving opportunities.
- Overseeing the maintenance and repair of plant equipment, ensuring optimal performance and minimizing downtime.
- Control on Store spare & maintenance cost.
- Preparing and analyzing production reports, performance metrics, and other relevant data to identify trends, track progress, MIS review and support decision-making.
- Working with other departments, such as sales, marketing, and engineering, to ensure seamless operations and meet customer needs.
- Contributing to the development and implementation of plant-level strategies to achieve long-term goals and objectives.
- BirlaNu Limited, formerly known as HIL Limited, is a building materials company and a part of the CK Birla Group. The company specializes in manufacturing and distributing a wide range of building solutions, including roofing, construction chemicals, Pipes & fittings and other materials. BirlaNu operates under various brands such as Charminar, Birla Aerocon, and Parador.
Manager production
Wavin India Pipes & Fittings Manufacturing Pvt. Ltd.
09.2021 - 12.2023
- Company Overview: Wavin is one of the leading PVC Pipe and fitting manufacturing company which is a part of Orbia group. Orbia have five group of companies like Duraline, Vestolite, Koura, Netafim & Wavin.
- Overall responsibility for Production Planning, production management, Quality of product and maintenance, customer complaint management, product development, BOM, costing & routing etc.
- Analysis of short fall in production & resources planning Viz man, machine material & space.
- Diagnose faults/malfunctions failure analysis Condition monitoring of Extrusion machines.
- Co-ordination with maintenance section for machine related problems.
- To review & monitor and control of Daily production of extrusion and Injection, set daily/weekly/monthly, make sure the operation is done as per the define SOP on Shop floor.
- Achieving desire level of productivity.
- To manage the production team in resolving breakdowns in minimum time, conduct discussion with plant team regarding breakdowns and planning for rectification with team.
- To manage the team to generate OEE & OEU data, identify the bottleneck of the process, carry out technical validation/revalidation with engineering team and Plant manager.
- Analyze production report against production plan. Take necessary action in case of any abnormalities.
- Provide all the production data and communicate abnormalities & critical issues (if any) to top management.
- Production, Rejection, down time analysis & making preventive action plan for rejection.
- Supervision and management of PVC/UPVC/CPVC Pipe, fitting, packing & compounding / Blending /mixer process with its additives formulation.
- Tool history monitoring and analysis and action plan for quality & productivity improvement.
- Line balancing: Tools tested on all suitable capacity line, fine tuning and establishing standard for hand over to Production, capacity utilization, tool sequencing to reduce tool change over time.
- Test runs: Testing of tools with new recipes, modification in case of engineering change.
- Optimizing the output and meter weight of profile along with production in charge for cost and productivity. (Weight optimization).
- Review corrective and preventive action (CAPA) - To keep control on deviation.
- Review of the production status w.r.t dispatch plan and production target on weekly basis. & Maintain sufficient stock of pipe & fittings as per declared MSL.
- Cost & Budget planning, scheduling, monitoring, and execution & managing of operations without cost over runs.
- Responsible to Plan, organize, Manufacturing teams in implementing improvement projects such as Lean Manufacturing and arrange for resources, conduct project reviews, identify gaps, take Corrective actions based on project.
- Responsibility to maintain Scrap reduction within budget.
- Responsible for overweight saving, Rejection by QA, regrind stock, Manage all tooling updated and available, Process failure/delay analysis.
- Successful Audit & renewal of ISO: 9001,14001 & OSHAS 18001 by documentation.
- To manage all leaves & attendance/permissions of all production employee.
- Annual performance review of all production Employee with in the define budget.
- Wavin is one of the leading PVC Pipe and fitting manufacturing company which is a part of Orbia group. Orbia have five group of companies like Duraline, Vestolite, Koura, Netafim & Wavin.
Manager production
DURALINE INDIA PVT LTD
09.2007 - 09.2020
- Company Overview: Duraline is a manufacturer and supplier of world class HDPE water pipes and telecom ducts for infrastructure development. Duraline India is an ISO 9001:2000 and ISO 14001 certified company.
- Duraline is a manufacturer and supplier of world class HDPE water pipes and telecom ducts for infrastructure development. Duraline India is an ISO 9001:2000 and ISO 14001 certified company.
Production Engineer
PRECISION PIPES AND PROFILES CO.LTD.
02.2007 - 09.2007
- Company Overview: PPAP is a leading manufacturer of high quality automotive sealing systems and exterior products in India. The company has manufacturing facilities in Delhi and Noida. All the plants are TS-16949, ISO-14001 and OHSAS-18001 certified. PPAP has a joint venture with Tokai Kogyo Co. Ltd, Japan for manufacturing Plastic Extrusion. Company has adopted MPS (Maruti production system) TPS (Toyota Production system). PPAP customers include some of the best automotive manufacturers in the Indian automotive market like Maruti Suzuki, Honda, Toyota and General Motors. PPAP has been awarded the best vendor awards year after year by its esteemed customers.
- PPAP is a leading manufacturer of high quality automotive sealing systems and exterior products in India. The company has manufacturing facilities in Delhi and Noida. All the plants are TS-16949, ISO-14001 and OHSAS-18001 certified. PPAP has a joint venture with Tokai Kogyo Co. Ltd, Japan for manufacturing Plastic Extrusion. Company has adopted MPS (Maruti production system) TPS (Toyota Production system). PPAP customers include some of the best automotive manufacturers in the Indian automotive market like Maruti Suzuki, Honda, Toyota and General Motors. PPAP has been awarded the best vendor awards year after year by its esteemed customers.
Production Engineer
PLASOPAN ENGINEERS (I) PVT. LTD
09.2002 - 02.2007
- Company Overview: M/S PLASOPAN is manufacturing in PVC profiles like door, Windows, ceiling, paneling & industrial sections also. Company has 18 Extruders for PVC manufacturing & manufacturing the PVC granules for self-use.
- M/S PLASOPAN is manufacturing in PVC profiles like door, Windows, ceiling, paneling & industrial sections also. Company has 18 Extruders for PVC manufacturing & manufacturing the PVC granules for self-use.
Education
Post Graduate Diploma - Business Administration
SCDL (symbiosis center for distance learning)
B.Sc. - undefined
C.C.S.University
S.S.S. - undefined
Allahabad Board
Allahabad, U.P.H.S.C. - undefined
Allahabad Board
Allahabad, U.P.Post Graduate Diploma - Plastics Processing & Testing
CENTRAL INSTITUTE OF PLASTIC ENGINEERING & TECHNOLOGY (CIPET)
Skills
Waste minimization
Operations management
Health and safety compliance
Cost controls
Quality assurance
Employee hiring
Adaptability
Effective communication
Plant maintenance
ISO standards
Certification
Lean manufacturing certification/ Lean leader training, 2018, Israel
Mobile Numbers
- 09950525076
- 07742757074
Disclaimer
06/07/25, Faridabad, RAHUL KUMAR
Personal Information
- Category: General
- Father's Name: Shri Jugpal Singh
- Date of Birth: 07/07/80
- Gender: Male
- Nationality: Indian
- Marital Status: Married
- Religion: Hindu
Timeline
Plant Head
BirlaNu Limited
01.2024 - Current
Manager production
Wavin India Pipes & Fittings Manufacturing Pvt. Ltd.
09.2021 - 12.2023
Manager production
DURALINE INDIA PVT LTD
09.2007 - 09.2020
Production Engineer
PRECISION PIPES AND PROFILES CO.LTD.
02.2007 - 09.2007
Production Engineer
PLASOPAN ENGINEERS (I) PVT. LTD
09.2002 - 02.2007
Post Graduate Diploma - Business Administration
SCDL (symbiosis center for distance learning)
B.Sc. - undefined
C.C.S.University
S.S.S. - undefined
Allahabad Board
H.S.C. - undefined
Allahabad Board
Post Graduate Diploma - Plastics Processing & Testing
CENTRAL INSTITUTE OF PLASTIC ENGINEERING & TECHNOLOGY (CIPET)