Sanjay Kaushik

Role Summary:
Oversee and manage operations of three manufacturing plants specializing in blow molding and pipe extrusion. Drive production efficiency, ensure quality standards, and provide technical support to achieve organizational goals.

Key Responsibilities:

Plant Operations Management:

• Supervise daily operations across three plants, ensuring efficient production and timely delivery.
• Monitor and optimize resource utilization and production schedules.
  

Technical Leadership:

• Provide expertise in blow molding and pipe extrusion processes to resolve technical issues and reduce downtime.
• Implement innovative solutions to enhance production capabilities.
  

Process Optimization:

• Identify and execute process improvements to increase efficiency and reduce waste.
• Apply Lean Manufacturing principles and other methodologies for continuous improvement.
  

Team Oversight:

• Lead and mentor plant managers and technical teams to maintain high performance.
• Ensure skill development through training programs.
  

Quality and Compliance:

• Maintain strict adherence to quality standards, safety protocols, and regulatory requirements.
• Oversee quality assurance processes to meet customer expectations.
  

Cross-functional Collaboration:

• Work closely with supply chain, R&D, and sales teams to align production with market needs.
• Support new product development with technical and production inputs.
  

Cost and Resource Management:

• Manage budgets, control costs, and plan capital expenditures for all plants.
  

• All types of the Extrusion process, by Sentinel (USA) & Tandem high-speed twin screw extruder, ABF film Laminations, Cross link foam.
• Overall responsibility for production & quality, Coordination with marketing for production planning & as per projection fulfillment, customer requirement & support.
• Managing Warehouse for Semi-Finished Goods/Finished Goods.
• Plant Waste Management includes Recycle Process, Reusing and selling of Non-reusable scrap.
• Monitored and supported progress of plant production orders by managing shop capacity and loading functions at several facilities.
• Investigated and implemented ideas for quality improvement, increased productivity and cost reduction.
• Coordinated activities required to bring product to market, aligned teams and bridged gaps between different functions.
• Resolved issues quickly to maintain productivity goals.
• Determined suitable crew requirements, scheduled employees, and worked with human resources to meet changing production schedules.
• Studied department operations to assist with development of new or improved methods of tooling and production processes.
• Delivered direct feedback to senior management regarding project visibility and status.
• Managed internal operational standards and productivity targets.
• Monitored team budgets to keep projects on task and avoid waste.
• Reviewed maintenance and repair problems to determine appropriate action for resolution.
• Standardized production procedures, job roles, and quality assurance guidelines.
• Partnered with leadership on recruiting, hiring and coaching production personnel.
• Managed continuous improvement initiatives to drive gains in quality, flow, and output.
• Created streamlined production schedules and collaborated with production employees to communicate objectives and goals.
• Sourced materials to keep up with production goals and meet customer demands.
• Reviewed work for quality and compliance with company standards and design specifications.
• Estimated labor requirements to support anticipated workload.
• Wrote and conducted formal performance reviews for production personnel.
• Managed and implemented marketing activities through research and strategic planning.

• Planning & Control
• Working with White Goods
• Customer/Automotive molding- LG, Bajaj, Mahindra & Mahindra, Haier.
• Accomplished multiple tasks within established timeframes.
• Maintained professional, organized, and safe environment for employees and patrons.
• Cross-trained existing employees to maximize team agility and performance.
• With JIT system, Over all Plant Production Planning and Procurement of Raw Materials, BOP for Molding and Paint Shop/Assembly Line Division.
• Developed and maintained relationships with customers and suppliers through account development.
• Resolved staff member conflicts, actively listening to concerns and finding appropriate middle ground.
• Maximized performance by monitoring daily activities and mentoring team members.
• Onboarded new employees with training and new hire documentation.
• All inventory control & ensure timely delivery to Customer.
• Overall coordination with Plant & J.I.T Customer.
• Monitored and analyzed business performance to identify areas of improvement and make necessary adjustments.
• Planned and budgeted accurately to provide business with resources needed to operate smoothly.
• Improved safety procedures to create safe working conditions for workers.
• Communicated clearly with employees, suppliers and stakeholders to keep everyone on same page and working toward established business goals.
• Managed and motivated employees to be productive and engaged in work.
• Opened and closed location and monitored shift changes to uphold successful operations strategies and maximize business success.
• Defined clear targets and objectives and communicated to other team members.
• Evaluated employee performance and conveyed constructive feedback to improve skills.
• Used industry expertise, customer service skills and analytical nature to resolve customer concerns and promote loyalty.
• Planned, created, tested and deployed system life cycle methodology to produce high quality systems to meet and exceed customer expectations.
• Maintained positive customer relations by addressing problems head-on and implementing successful corrective actions.
• Identified and communicated customer needs to supply chain capacity and quality teams.
• Recruited, interviewed and hired employees and implemented mentoring program to promote positive feedback and engagement.

• Reduced costs by eliminating materials waste and unnecessary labor hours.
• Maximized plant safety through proactive strategies and well-structured training.
• Directed employees and related programs to maximize team productivity and facility output.
• Optimized processes to maximize efficiency.
• Managed direction and planning for plant with focus on optimization of daily functions, exceeding customer expectations, and achieving KPIs.
• Provided direction and leadership to all levels of employees and managers.
• Promoted collaborative work environment to motivate and engage staff to achieve company objectives.
• Oversaw routine maintenance programs and scheduled service to keep equipment functioning at peak levels.
• Analyzed production data and prepared reports for senior management.
• Enforced health and safety protocols to promote safe working environment.
• Scrutinized production output and identified areas for improvement.
• Created and oversaw production schedules and adjusted as needed to meet deadlines.
• Evaluated employee performance and provided feedback and training as needed.
• Planned operations to meet established schedules, factoring in order demands and business forecasts.
• Collaborated with technical and administrative teams to develop and implement successful corrective plans.
• Coordinated with other departments to align production with customer requirements.
• Monitored inventory levels and restocking schedules to avoid production delays from unavailable materials.
• Managed personnel by implementing company policies, procedures, work rules, and disciplinary action.
• Led, trained and coached plant staff to facilitate high levels of productivity and quality.
• Monitored and evaluated plant performance to identify areas for improvement and take corrective measures.

• Working as a Production, - all type of Extrusion process, by Sentional (USA) high speed twin screw extruder Laminations, Cross link foam.
• Managed continuous improvement initiatives to drive gains in quality, flow, and output.
• Reviewed work for quality and compliance with company standards and design specifications.
• Co-ordination with marketing for production planning & as per projection fulfillment, customer requirement & support.
• Resolved issues quickly to maintain productivity goals.
• Sourced materials to keep up with production goals and meet customer demands.
• Standardized production procedures, job roles, and quality assurance guidelines.
• Monitored team budgets to keep projects on task and avoid waste.
• Managed internal operational standards and productivity targets.
• Estimated labor requirements to support anticipated workload.
• Determined suitable crew requirements, scheduled employees, and worked with human resources to meet changing production schedules.
• Studied department operations to assist with development of new or improved methods of tooling and production processes.
• Partnered with leadership on recruiting, hiring and coaching production personnel.
• Wrote and conducted formal performance reviews for production personnel.
• Organized and detail-oriented with a strong work ethic.
• Developed strong organizational and communication skills through coursework and volunteer activities.
• Demonstrated leadership skills in managing projects from concept to completion.
• Acted as a team leader in group projects, delegating tasks and providing feedback.
• Excellent communication skills, both verbal and written.

• Mitigated regulatory risks by overseeing adherence to insurance and safety regulations.
• Employed optimal safety practices to reduce worksite complaints and hazards.
• Monitored industry trends, keeping current on latest changes and competition in industry.
• Demonstrated proficient leadership skills to motivate employees and build competent teams.
• Evaluated product development strategies and prepared alternative approaches to goal achievement.
• Production looking all type of Extrusion Process like EPE foam, Air Bubble film, Laminations, Printing .Internal co-ordination with dispatch & Production Planning & Quality Activities & also working As a Quality Head.
• Established performance goals for department and outlined processes for achievement.
• Collaborated with senior management to develop strategic initiatives and long term goals.
• Clarified roles, responsibilities and expectations of staff.
• Identified and resolved issues between employees, promoting better collaboration and mutual respect.
• Identified opportunities to improve business process flows and productivity.
• Increased company growth through collaboration with sales and marketing departments.
• Hired and managed employees to maximize productivity while training staff on best practices and protocols.
• Established performance goals for department and provided methods for reaching milestones.

• Met regularly with production team and managers to analyze problems and plan cost-effective and high-quality product delivery.
• Wrote standard operating procedures and adjusted policies to meet changing demands.
• Planned and assigned daily duties to staff members.
• Developed new ways of manufacturing and improved existing manufacturing processes.
• Observed production work and made corrective actions to optimize performance.
• Making Multi Layer Film famous for Extrusion/ Roto Graver/Flaxo printing & Supply all over M.P.
• Escalated concerns to management and helped develop and implement effective solutions.
• Evaluated incoming materials and finished products against standards.
• Coordinated production work between shifts by completing checklists and documenting updates.
• Recommended process improvements to enhance product quality.
• Reviewed production reports to spot and correct issues early.
• Managed resource utilization and continuous improvements to streamline operations and reduce costs.
• Determined best and most efficient uses of available resources, labor and equipment.
• Organized repair and routine maintenance of production equipment.
• Oversaw discipline, safety and good housekeeping systems.
• Created and implemented strategies for improving operational efficiency and accuracy.
• Reviewed documentation such as invoices and shipping paperwork for accuracy and compliance.
• Implemented policies and standard operating procedures for continuous improvement.
• Cultivated professional working relationships with peers and supervisors.
• Kept accurate and detailed records of personnel progress and productivity.
• Oversaw inventory and product stock to develop and maintain inventory controls resulting in cost savings and reduced overages.