RAJKUMAR PRAJAPAT
Ahmedabad
Summary
Results-driven and performance-focused Production Leader with 25 years of expertise in large-scale plant operations, production planning, quality assurance, and process optimization in the dairy and ice cream industry. Adept at managing end-to-end production processes with a capacity of 2 lakh liters/day, while maintaining stringent hygiene and food safety standards. Proven ability to drive productivity, minimize downtime, reduce waste, and ensure efficient manpower and resource utilization.
Overview
24
24
years of professional experience
1
1
Certification
Work History
Plant Head (Operations)
Kings Food Tech Pvt. Ltd.
Paithan , Ch. Shambhajinagar, Maharashtra
08.2025 - Current
- Overall responsibility for plant operations, ensuring safe, efficient, and cost-effective production.
- Lead and supervise production planning and execution to achieve quality, productivity, and delivery targets.
- Manage stores and inventory control, ensuring optimal stock levels and minimising wastage.
- Oversee purchase and procurement activities, including vendor development, negotiation, and cost control.
- Head engineering and maintenance functions to ensure high equipment reliability and minimal downtime.
- Coordinate with HR & Administration for manpower planning, training, statutory compliance, and discipline.
- Manage logistics and dispatch operations to ensure timely delivery and customer satisfaction.
- Ensure inter-departmental coordination for smooth plant functioning and operational excellence.
- Implement and monitor SOPs, safety standards, and statutory compliance across all departments.
- Drive continuous improvement initiatives to enhance productivity, quality, and cost efficiency.
Production head (Sr. Production Manager)
HAVMOR ICE CREAM LTD.
Ahmedabad
01.2011 - 07.2025
- Direct end-to-end production operations in a state-of-the-art ice cream plant with a daily capacity of 2,00,000 liters, ensuring consistent output while maintaining strict food safety and hygiene standards.
- Supervise all stages of ice cream manufacturing including mixing, pasteurization, batching, freezing, extrusion, candy production, and packaging.
- Develop and execute daily, weekly, and monthly production schedules to meet customer demand, optimizing labor and equipment resources.
- Oversee inventory control for raw materials, semi-finished products, and packaging items while ensuring minimal wastage and cost control.
- Plan and coordinate preventive maintenance schedules of machines to minimize unplanned downtime and ensure continuous production.
- Conduct root cause analysis (RCA) for production issues and implement corrective and preventive actions (CAPA) to avoid recurrence.
- Work closely with R&D for trial runs of new product varieties and flavors, including stickless, extrusion, and candy products.
- Lead cross-functional coordination among QA, Maintenance, Stores, and Logistics teams to streamline plant efficiency.
- Monitor and analyze KPIs such as yield %, line efficiency, machine utilization, and labor productivity for continuous improvement.
- Implement and enforce compliance with ISO 22000, FSSAI, and company SOPs to maintain world-class hygiene standards.
- Provide training and guidance to production teams to improve technical skills and adherence to safety protocols.
- Contribute to plant expansion projects including equipment selection, layout design, and commissioning of new lines.
- A Lotte Confectionery Company, MNC
Senior Production Officer
AMUL - MOTHER DAIRY
Gandhinagar
09.2001 - 12.2010
- Managed day-to-day production activities in Asia's largest dairy processing plant, specializing in ice cream, UHT milk, butter, and other dairy products.
- Led the operations of a 1,00,000 LPD ice cream plant, overseeing batching, freezing, blending, and final packaging processes.
- Planned and managed material flow, stock levels, manpower rosters, and production schedules using ERP.
- Implemented SAP for production and material data management across 5 union dairies, collaborating with TCS teams during data migration.
- Coordinated with maintenance and QA teams to ensure equipment functionality and compliance with safety norms.
- Conducted energy audits and implemented cost control measures that reduced utility consumption significantly.
- Ensured adherence to ISO 9000:2000, GMP, and HACCP standards across production operations.
- Facilitated employee skill enhancement programs and process standardization for consistent product quality.
- GCMMF
- Key member of SAP implementation for the entire ice cream division across federations.
- Played an instrumental role in process automation and documentation as per ISO standards.
- Reduced material loss and improved overall process yield by initiating line balancing techniques.
- Ensure 5S, GMP, and TPM practices are followed rigorously across the plant to enhance safety and cleanliness.
- Maintain documentation for internal audits, customer audits, and certifications.
- Successfully led the installation and commissioning of new production lines, increasing capacity and variety offerings.
- Reduced production downtime by 20% through efficient maintenance planning and real-time monitoring.
- Improved yield and material utilization by optimizing batch formulations and minimizing process losses.
- Spearheaded cost-saving initiatives in energy and material usage, contributing significantly to bottom-line savings.
- Achieved consistent compliance in third-party audits including FSSAI and ISO 22000 audits with excellent scores.
Education
B.Tech - Dairy Technology
MPUAT
Udaipur01.2001
Skills
- Strategic production planning
- Line optimization
- End-to-end manufacturing operations
- Quality control and assurance
- ISO 22000 and ISO 9000
- Food safety management
- Cross-functional leadership
- Manpower planning and development
- Plant expansion strategies
- Layout design and development
- SCADA systems expertise
- Auto CIP systems knowledge
- Freezer machinery operation
- Packaging machinery proficiency
- SAP and ERP systems
- TCS systems management
- Material and inventory management
- Total productive maintenance (TPM)
- Total quality management (TQM)
- ISO documentation and compliance audits
Certification
- ERP (TCS) - Material Management Implementation
- Internal Auditor Training - ISO 9002 & ISO 14001
- Total Quality Management (TQM) & Total Productive Maintenance (TPM) - 3-day workshop
- Quality Management System Workshop - DNV, Baroda
- Seminar on TPM - Ahmedabad Management Association
Languages Known
English
Hindi
Gujarati
Rajasthani
Custom Section
- Windows
- UNIX
Systems
- SAP
- ERP
- SCADA
Timeline
Plant Head (Operations)
Kings Food Tech Pvt. Ltd.
08.2025 - Current
Production head (Sr. Production Manager)
HAVMOR ICE CREAM LTD.
01.2011 - 07.2025
Senior Production Officer
AMUL - MOTHER DAIRY
09.2001 - 12.2010
B.Tech - Dairy Technology
MPUAT