Sachin Dharane
Summary
Highly accomplished professional with 16+ years of experience spanning Renewable Energy CBG and Operational Excellence. Master of Engineering from BITS Pilani and Certified Lean Six Sigma Black Belt. . Expert in driving multi-million dollar savings through Six Sigma, Lean, and continuous improvement methodologies.
Overview
4
4
Languages
1
1
Certification
19
19
years of professional experience
Work History
Sr. Manager Project Development & Operations
CleanEdge Resources Pvt. Ltd.
08.2024 - Current
- Negotiated and secured CBG off-take agreements and long-term feedstock supply contracts, ensuring stable supply and market viability.
- Manage all statutory approvals including PESO and Pollution Control Board (CTE/CTO); facilitate government subsidy applications (CFA).
- Serve as primary point of contact for resolving complex on-site technical and logistical constraints.
- Liaise with commissioning teams to verify plant performance and ensure smooth transition to operations.
- Apply Lean Six Sigma and Kaizen methodologies to optimise gas yield and maximise plant uptime.
- Oversee end-to-end supply chain: procurement, pre-treatment, and inventory management of feedstock.
- Lead technical and legal due diligence for project land acquisition and Napier grass farming clusters.
- Assisted in lead identification and technical evaluations, strengthening CBG project pipeline and supporting strategic project development.
- Established distribution and marketing channels for organic fertiliser, enhancing accessibility for farming sector end consumers.
- Provide site-specific constraints to design teams to align plant configurations with client needs.
Founder
Dharane Biofuel Private Ltd.
01.2020 - 07.2024
- Developed and launched startup centred on bio-based solutions, addressing sustainability challenges in agriculture.
- Promoted the concept of circular bioeconomy by producing biofuels and bioproducts, uplifting farmer income without harming the ecosystem.
- Installed pilot plant for Bio-CNG using Napier grass and cow dung as substrate; established in-house lab for testing raw materials and in-process parameters, enhancing product quality.
- Promoted 50+ farmers to utilise agri-waste as organic fertiliser (previously burnt), reducing emissions and improving soil health.
- Hands-on experience in Napier grass farming, harvesting, and biomass testing; demonstrated farming on 20 acres across varying soil conditions.
- Conducted seminars on organic farming and facilitated conversion of 40 acres to organic practices; ran ecosystem restoration webinars for colleges, schools, and local farmer groups, fostering community engagement.
Senior Manager - Operational Excellence
Myntra Private Ltd.
01.2019 - 12.2020
- Identified and executed Operational Excellence opportunities across organisation, enhancing safety, quality, delivery, cost and people (SQDCP) metrics.
- Delivered 189 Kaizens, generating cost savings of ₹23 Lakhs per annum.
- Led and facilitated Kaizen events achieving strategic targets; implemented 5S across the fulfilment centre.
- Reduced customer cancellations from 0.10% to 0.07% through structured Kaizen events.
- Reduced shortages per lot from 1.58 to 1.24 by improving process flow.
- Conducted GEMBA walks with Site Head, pinpointing improvement areas and monitoring progress towards operational goals.
- Devised and implemented performance measurement tools aligned to the business plan.
Assistant Manager - Operational Excellence
Sandoz Private Ltd.
01.2016 - 12.2019
- Improved OEE of compression machine from 21% to 35%; packaging line from 20% to 38%.
- Achieved utility cost reduction of 22% through heat pump & LED implementation - saving 0.8 million USD.
- Reduced changeover time of compression machine by 3 hours, enhancing operational efficiency.
- Mentored 9 Green Belt projects across Supply Chain, Quality, Manufacturing, Packaging, and Finance, contributing to total savings of 0.4 million USD.
- Reduced overdue compliance activities from 89 to 9 via Rapid Kaizen event.
- Trained 180 associates in Lean Management and Six Sigma basics, fostering a culture of continuous improvement.
Assistant Manager - Operational Excellence
Dr. Reddy's Laboratories Ltd.
01.2015 - 12.2016
- Mentored 4 Black Belt and 5 Green Belt projects - saving 0.7 million USD per annum.
- Led plant in Indian Manufacturing Excellence Award (IMEA) - secured Gold Medal.
- Enhanced OEE of compression machine from 33% to 42%, contributing to overall operational efficiency.
- Reduced coating machine cycle time from 42 hrs to 25 hrs.
- Improved product robustness: process capability from Cpk 0.75 to 1.23.
- Increased yield of top-runner products, resulting in savings of 0.3 million USD per annum.
- Delivered Lean Six Sigma White Belt training to 150 associates, fostering a culture of continuous improvement.
Assistant Manager - Continuous Improvement
LPS Private Ltd.
01.2013 - 12.2015
- Reduced in-house rejection at finishing operation from 11.08% to 2.7% - saving 0.1 million USD/annum; production increased from 8.1 MT/day to 9.6 MT/day.
- Reduced rolling machine rejection from 277,750 PPM to 0 PPM - saving ₹80 Lakhs/annum; appreciated by Director of Maruti Suzuki.
- Increased rolled throughput yield of plating process from 87% to 92% - saving ₹90 Lakhs/annum.
- Reduced customer complaints (line irritants) in forging from 77% to 10%, enhancing customer satisfaction and product quality.
- Reduced forging machine set-up time from 282 min to 210 min using SMED, improving overall operational efficiency.
- Increased Kaizen rate from 0.32 to 0.56 per employee per month, fostering a culture of continuous improvement.
- Deployed Lean Six Sigma; trained 16 colleagues - 10 achieved Green Belt certification.
- Trained 88 colleagues on 7QC Tools, Problem-Solving, SPC, MSA, and Lean Six Sigma.
Sr. Engineer - R&D
Kirloskar Pneumatic Private Ltd.
01.2008 - 12.2010
- Conducted analysis for NPD and designed bill of materials, ensuring accurate release process.
- Coordinated with internal departments to manufacture newly developed products; prepared and authorised engineering drawings for production.
- Developed specification data sheets to support New Product Development of bought-out items.
Education
Master of Engineering - Manufacturing System Engineering
BITS Pilani
01-2013
Bachelor of Engineering - Mechanical Engineering
Government College of Engineering, Amravati
01-2008
Skills
- Renewable Energy
- CBG / Bio-CNG / Biogas Plant Operations
- Site Due Diligence & Land Acquisition
- Napier Grass Farming
- Harvesting & Biomass Management
- Anaerobic Digestion & Feedstock Supply Chain
- PESO / PCB Regulatory Compliance & Subsidy Facilitation
- Organic Farming & Ecosystem Restoration
- Lean Six Sigma (DMAIC, PDCA, Rapid Kaizen, Toyota KATA)
- SPC
- MSA
- DOE
- FMEA
- OEE & Process Capability
- 5S
- Value Stream Mapping
- TPM
- SMED
- MIS / Data Analysis / Minitab & MS Office
- Team Leadership
- Training & Green/Black Belt Mentoring
- CBG Off-take Agreements & Stakeholder Liaison
Languages
Marathi
Hindi
English
Kannada
Certification
▸ Certified Lean Six Sigma Black Belt — Ranked
2nd in batch (Score 91%)
▸ GATE Qualified — IIT Bombay, 2011
▸ Certified AS 9100 Rev C Internal Auditor
▸ Certified in CATIA & AutoCAD
▸ Basics of Biogas (Certified)
Accomplishments
▸ IMEA Gold Medal — Indian Manufacturing
Excellence Award
▸ Best Performance Award — OAE Improvement &
Training
▸ Appreciation from Maruti Suzuki Director — Lean
Six Sigma Projects
▸ Appreciation from ISO/TS 16949 & AS 9100
Auditors
▸ Appreciation from CMD for 5S Implementation
Workshop and Tranings
▸Pharma Operational Excellence Summit — Mumbai
▸ CII 5th Lean Six Sigma Summit — Delhi
▸ 21-Day Basic Mechanical Workshop Skills — Tata Motors, Pune
▸ 10-Day Management Boot Camp — KIAMS (Kirloskar Institute of Advanced Management Studies), Harihar
Timeline
Sr. Manager Project Development & Operations
CleanEdge Resources Pvt. Ltd.
08.2024 - Current
Founder
Dharane Biofuel Private Ltd.
01.2020 - 07.2024
Senior Manager - Operational Excellence
Myntra Private Ltd.
01.2019 - 12.2020
Assistant Manager - Operational Excellence
Sandoz Private Ltd.
01.2016 - 12.2019
Assistant Manager - Operational Excellence
Dr. Reddy's Laboratories Ltd.
01.2015 - 12.2016
Assistant Manager - Continuous Improvement
LPS Private Ltd.
01.2013 - 12.2015
Sr. Engineer - R&D
Kirloskar Pneumatic Private Ltd.
01.2008 - 12.2010
Master of Engineering - Manufacturing System Engineering
BITS Pilani
Bachelor of Engineering - Mechanical Engineering
Government College of Engineering, Amravati