RANJEET MAHAPATRA
AVP Operation And Manufacturing Excellence
Gandhinagar
Summary
Accomplished manufacturing leader with nearly 24 years of progressive experience in the Flexible Packaging Industry across India and international markets. Extensive expertise in Plant Operations, Manufacturing Excellence, Operational Transformation, Strategic Leadership, Process Optimization, Quality Systems, Cost Reduction, Productivity Improvement, Safety Management, and Customer-Centric Manufacturing Operations. Proven capability in leading large-scale flexible packaging operations covering Blown Film Extrusion, Rotogravure Printing, CI Flexo Printing, Adhesive Lamination, Extrusion Lamination, Slitting, Pouch Making, and High-Barrier Multilayer Film Manufacturing. Recognized for driving operational excellence initiatives through Lean Manufacturing, TPM, Six Sigma, process standardization, and strong people leadership. Experienced in building high-performance teams, improving operational stability, reducing manufacturing losses, enhancing customer satisfaction, and creating sustainable manufacturing systems.
Overview
4
4
Languages
25
25
years of professional experience
Work History
AVP Operations & Manufacturing Excellence
PPL
01.2026 - Current
- Leading overall manufacturing operations with strategic focus on Safety, Quality, Delivery, Cost, Productivity, and Customer Satisfaction.
- Driving operational excellence roadmap through Lean Manufacturing, TPM, Six Sigma, digitalization, and automation initiatives.
- Leading manufacturing transformation initiatives focused on operational stability, process standardization, and profitability improvement.
- Strengthening plant safety systems including solvent handling safety, VOC management, static electricity control, emergency preparedness, and compliance systems.
- Driving zero customer complaint culture through robust process discipline and process control systems.
- Reviewing critical KPIs including OEE, rejection, downtime, OTIF delivery, inventory, utility consumption, and manpower productivity.
- Building second-line leadership capability through succession planning, performance reviews, and capability development.
Plant Head
Phoenix Flexibles Pvt. Ltd. (Amcor)
07.2023 - 01.2026
- Led complete plant operations including Production, Engineering, Maintenance, Quality, SCM, EHS, and Warehouse functions.
- Improved operational efficiencies and manufacturing reliability through structured operational control systems and performance monitoring.
- Led manufacturing excellence initiatives focused on productivity enhancement, waste reduction, conversion cost optimization, and process discipline.
- Strengthened plant safety culture and ensured compliance with corporate and statutory safety requirements.
- Led CAPEX planning, process improvement initiatives, operational reviews, inventory optimization, and customer-focused manufacturing systems.
- Developed strong cross-functional accountability culture and improved operational responsiveness across departments.
Operations Manager
Amcor Flexible India Pvt. Ltd.
03.2021 - 06.2023
- Managed daily manufacturing operations ensuring optimum manpower and machine utilization.
- Led process enhancement initiatives through operational gap analysis and corrective action implementation.
- Developed SOPs, process monitoring systems, operational controls, and production standards.
- Strengthened workplace safety practices, process compliance, housekeeping systems, and operational discipline.
- Improved coordination between production, maintenance, quality, and planning functions for uninterrupted operations.
Operations Manager
Bhojraj Industries Ltd., Lagos, Nigeria
08.2019 - 03.2021
- Managed high-volume flexible packaging operations catering to leading FMCG customers across Nigeria.
- Handled advanced manufacturing systems including Bobst Rotogravure Printing Machines, Nordmeccanica Laminators, Bobst Nova Tandem Laminators, and W&H Blown Film Lines.
- Improved machine productivity, operational reliability, and manufacturing discipline through strong shop-floor leadership.
- Managed multicultural workforce and strengthened customer-focused manufacturing practices in international operations environment.
- Led production planning, manpower optimization, process control, and operational improvement initiatives.
Previous Leadership Roles
01.2001 - 01.2019
- Held progressive leadership roles with Amcor Flexible India, UFlex, Umax Packaging, Glory Polyfilms, and Aakash Group.
- Managed flexible packaging manufacturing operations including printing, lamination, blown film, slitting, and pouching.
- Led production planning, process quality assurance, inventory coordination, manpower management, and operational excellence initiatives.
- Developed strong expertise in process optimization, customer compliance, manufacturing systems, and shop-floor management.
Education
MBA - Operations Management
SMU
01.2009
Diploma - Plastics Processing & Conversion Technology
CIPET Hyderabad
01.2001
B.Sc. - undefined
Berhampur University
01.1999
Skills
Plant Operations Management
Manufacturing Excellence
Operational Excellence & TPM
Lean Manufacturing & Kaizen
Strategic Leadership
Cost Optimization & Productivity Improvement
Safety, Health & Environment (SHE)
Quality Systems & Customer Compliance
Production Planning & Process Control
CAPEX & Automation Projects
EXECUTIVE LEADERSHIP HIGHLIGHTS
- Nearly 24 years of leadership experience in flexible packaging manufacturing operations.
- Strong exposure in multinational manufacturing environments including Amcor and international operations in Nigeria.
- Expertise in handling complete plant operations including Production, Engineering, Maintenance, Quality, SCM, EHS, Warehouse, and Operational Excellence.
- Led manufacturing transformation initiatives focused on productivity enhancement, waste reduction, operational discipline, and profitability improvement.
- Strong exposure in customer audit handling, GMP, HACCP, BRCGS, safety systems, and process compliance.
- Experienced in leading Lean Manufacturing, TPM, Kaizen, CAPEX, automation, and continuous improvement initiatives.
- Strong capability in people development, succession planning, leadership building, and cross-functional management.
Timeline
AVP Operations & Manufacturing Excellence
PPL
01.2026 - Current
Plant Head
Phoenix Flexibles Pvt. Ltd. (Amcor)
07.2023 - 01.2026
Operations Manager
Amcor Flexible India Pvt. Ltd.
03.2021 - 06.2023
Operations Manager
Bhojraj Industries Ltd., Lagos, Nigeria
08.2019 - 03.2021
Previous Leadership Roles
01.2001 - 01.2019
B.Sc. - undefined
Berhampur University
Diploma - Plastics Processing & Conversion Technology
CIPET Hyderabad
MBA - Operations Management
SMU