Rushikesh Vaidya

Skilled Packaging Professional with extensive experience in end-to-end packaging design and development, including Innovator Sample Analysis, Packaging Dossier Finalization, and Machine Change Parts Development. Proficient in Artwork Development, Packaging Validation Strategy and Management, and implementing Trace and Track systems for serialization and aggregation. Demonstrated expertise in Packaging Testing Design, Vendor Development and Compliance, and crafting SOPs and STPs to provide operational guidance to manufacturing plants. Successfully managed diverse product formulations, including solid orals, injectables, and powders, ensuring compatibility, quality, and compliance across all packaging solutions.

Experienced in audit preparation and management, including successfully passing rigorous audits from regulatory bodies such as USFDA, MHRA, and other international agencies. Proactively developed and maintained documentation and validation protocols to meet and exceed regulatory standards, ensuring smooth audit processes and compliance alignment across the packaging lifecycle.

Key Contributions:

• Successfully managed the packaging and regulatory filing of approximately 350 products across diverse formulations, including solids, injectables, and powders.
• Implemented bracketing for stability testing of new product packs, optimizing the testing process and reducing resource usage.
• Established a change part qualification system to streamline and reduce validation exercises at the plant level.
• Deployed a comprehensive Packaging Validation Strategy, successfully passing audits from regulatory bodies including USFDA, MHRA, Kenya, and Zambia.
• Replaced plastic drums with blue plastic shippers for bulk exports to the EU market, maximizing pallet utilization, simplifying shop floor handling, and optimizing warehouse space.
• Removed outer cartons for ARV products as part of a COGS improvement project, reducing packaging costs.
• Led the implementation of the Trace and Track (Serialization and Aggregation) project at the Mylan Nashik site for all product packs.
• Introduced a new peel-back design for peelable paper blisters in the EU and AUS markets, improving handling and significantly reducing market complaints.
• Spearheaded artwork preparation and final approvals, ensuring packaging material specifications met quality and compliance standards.
• Conducted competitor analysis through reverse engineering to drive technical insights and innovation strategies.
• Standardized packaging material specifications, providing vendors with SOP-compliant data to ensure quality consistency.
• Performed supplier Certificate of Analysis (COA) verification upon receipt to confirm adherence to specifications.
• Conducted Root Cause Analysis (RCA) for manufacturing incidents, implementing corrective and preventive actions based on in-depth reviews.
• Authored and maintained essential documentation, including MVTR reports, Certificates of Analysis, Letters of Authorization (LOAs), and Drug Master File (DMF) approvals.
• Initiated change controls for new product launches across the EU, US, and Canada markets to ensure regulatory compliance.
• Developed and reviewed Master Packaging Configurations (MPCs) for new and post-launch products in EU, US, Canada, and ARV markets, aligning with market-specific requirements.

Project and Cost Management for Packaging and Product Launches:

• Led Cost of Goods Sold (COGS) optimization projects, implementing strategies to reduce costs across bottles, labels, cartons, and glass bottles.
• Supported new product launches by ensuring sufficient preparation time and resources for successful market entry.
• Managed critical projects for products such as bleach, foundation, HRC, compact powders, and talcum, ensuring timely execution and quality.
• Developed and onboarded new vendors to diversify supply chain capabilities and support packaging innovation.
• Addressed and resolved plant-related issues efficiently to maintain smooth production operations.
• Oversaw the procurement of new machinery for lotion and powder filling, enhancing production capacity.
• Coordinated closely with the marketing team to fulfill requirements for promotional materials, including wobblers, danglers, shelf strips, stackers, and brochures.
• Supported the Digital Marketing team by introducing new packaging design concepts to enhance brand appeal.
• Played a key role in cost reduction and new product development initiatives, contributing to the launch of nine new brands under Olivia.

Packaging Management for International and Domestic Markets:

• Oversaw end-to-end packaging processes from primary to tertiary packaging, including both flexible and rigid materials, to ensure quality and efficiency.
• Conducted Quality Control of packaging products to maintain high standards and compliance with specifications.
• Managed purchase orders for packaging materials, ensuring timely procurement aligned with production needs.
• Addressed and resolved online production line issues related to packaging materials, maintaining seamless production flow.
• Developed various packaging solutions tailored to client requirements, including bottles, jars, caps, pouches, tubes, monocartons, inner cartons, display cartons, shrink wraps, and outer cartons.
• Established and nurtured vendor relationships for key materials such as outer cartons, monocartons, shrink wraps, and labels, optimizing quality and cost efficiency.

• Partnered with Calpoly University, USA, and the International Safe Transit Association (ISTA) to develop transportation standards specifically for India.
• Worked with prominent clients, including Aditya Birla, Godrej, Marico, Amazon, Cipla Pvt. Ltd., and Lupin Pvt. Ltd.
• Managed primary, secondary, and tertiary packaging for various products, including aerosol sprays, cans, blister packs, bottles, boxes, cartons, barrels, containers, and edge containers, ensuring optimized compatibility and performance.
• Oversaw warehousing and supply chain management to improve logistics efficiency.
• Conducted rigorous packaging material testing—including drop, vibration, shock, inclined impact, WVTR (Water Vapor Transmission Rate), OTR (Oxygen Transmission Rate), leakage, and product compatibility tests—following industry standards to guarantee packaging durability and quality.