SANJAYA D P
Assistent Manager - Production
Bengaluru
Summary
Dynamic and results-oriented professional with 10 years of experience in production, operations, and continuous improvement across high-speed bottling lines in beverages and brewery operations, as well as food manufacturing environments. Demonstrated expertise in operational excellence, quality improvement, and cross-functional leadership to deliver sustainable business results.
Overview
9
9
years of professional experience
1
1
Certification
4
4
Languages
Work History
Assistant manager
Monin India Private Limited
08.2025 - Current
- Ensured compliance with Monin product standards and full filaments of local and export customer demand
- Led end-to-end manufacturing operations including syrup processing, bottling, and packing
- Improved productivity and reduced waste, cost, and resource consumption through process optimization
- Maintained strong quality, food safety, and regulatory compliance across operations
- Optimized production planning and capacity utilization to meet targets and improve throughput
- Drove continuous improvement and people development, focusing on safety, line efficiency, labour productivity, water usage, variable cost, and customer complaints
- Ensured zero LTI, safe working conditions, and compliance through audits and risk controls
- Supported new product commercialization in collaboration with R&D
- Production Line: Syrup preparation, Glass & PET line
Assistant manager
Orkla Foods ltd
02.2022 - 08.2025
- Accountable for end-to-end delivery of production KPIs such as:-
- Safety: Ensured zero-harm culture through audits, PPE compliance, and behavior-based safety programs.
- Quality: Maintained process compliance with PTS and CCP; implemented corrective actions based on RCA/5Why.
- Productivity: Improved line OEE and reduced idle time through shift optimization and equipment reliability.
- Cost: Controlled material variance and labor utilization; led cost-saving initiatives using PDCA and FP&R.
- Lead EHS and Quality implementation initiatives, ensuring alignment with global safety standards and audit readiness.
- Optimize the use of Man, Machine, and Materials, ensuring maximum productivity through direct floor involvement and cross-functional alignment.
- Guide production line teams in real-time problem solving, quality deviation handling, and shift planning.
- Ensure manpower planning including crewing, rotation, and leave management to maintain operational continuity.
- Drive floor engagement through coaching, daily walkarounds, feedback loops, and 5S, AM, and PM meetings.
- Manage routine maintenance and repair schedules while maintaining critical spare part inventory.
- Conduct technical skill development sessions for both technicians and line team members to build capability and autonomy.
- Production Line: Sweet mix, Health drink mix, Instant food & Vermicelli
Production Executive
Carlsberg (Mysore)
04.2021 - 02.2022
- Led end-to-end plant operations planning and execution aligned with business goals and market demand
- Delivered cost, quality, and delivery targets through disciplined planning, reviews, and team leadership
- Drove continuous improvement programs (LEAN, TPM, VPO) to enhance efficiency, yield, and productivity
- Implemented integrated quality, safety, and planning governance aligned with ISO and FSSC standards
- Translated strategic objectives into execution using tiered huddles, visual dashboards, and action plans
- Managed daily production scheduling aligned with demand forecasts and resource availability
- Improved lead time and capacity utilization through effective shift, manpower, and capacity planning
- Ensured audit readiness, zero-harm culture, and compliance in collaboration with HSE and QA teams
- Production Line Capacities: line 28000BPM
Production Executive
Ab-InBev (Mysore)
08.2016 - 04.2021
- Led daily DRM, shift handover, asset care, and review meetings, ensuring production plan adherence and issue resolution
- Executed production as per daily, weekly, and monthly plans with strict compliance to quality, safety, and PTS/CCP requirements
- Planned and optimized resources (manpower, machines, packaging materials), including effective contract manpower deployment
- Ensured zero safety incidents through PPE compliance, LOTO/SAM, hazard identification, SIF precursor tracking, and continuous safety training
- Drove VPO / Manufacturing Excellence initiatives including 5 Why, PDCA, A3/AB Reports, ITF, delivering cost and efficiency improvements
- Improved KPIs (GLY, LEF, MTBF, MTTR) through structured loss analysis (Pareto, Waterfall) and root cause actions
- Delivered extensive operator capability building (≈800 training hours) on VPO, KPIs, and workstation effectiveness (C2C)
- Managed material reconciliation, stock taking, job closing, and detailed loss & wastage analysis
- Executed and supported operation, preventive & breakdown maintenance of RGB & CAN lines (Krones, Sidel, KHS)
- Coordinated with Brewing, QA, HSE, Logistics, Maintenance, and Supply Chain teams to ensure uninterrupted production
- Production Line Capacities: RGB line 36000Bpm, Can line 12000Cpm, Keg line
Education
Bachelor of Engineering - Electrical & Elecrtonics
Sri Jayachamarajendra College of Engineering
Mysore, IndiaDiploma - Electrical & Electronics
Rajiv Gandhi Memorial Polytechnic College
Bengaluru, India 04.2001 -
A Division of Toyota Kirloskar Motor - Mechatronics
Toyota Technical Training Institute
BengaluruSkills
Specialized in Mechatronics in Toyota Technical Training Institute
High-Speed Manufacturing Line Operations (RGB, Can, Keg, Syrup, Food Processing)
Packaging & Bottling Technologies (Krones, Sidel, KHS, CFT, PE, Perrior, Clevertech)
Project Installation, Erection & Commissioning of Production Lines
Food Processing Technologies (Dry Mixing, Roasting, Blending, Extrusion, Vermicelli Processing)
Beverage & Health Drink Processing (Badam Drink, Sweet Mixes, Instant Food Products)
PLC & Automation Basics (Siemens S7, B&R, Danfoss Drives, HMI)
Lean Manufacturing, VPO, TPM & Continuous Improvement Tools
Accomplishments
- Erection, Commissioning & Expansion of high speed lines (PET,RGB CAN & KEG)
- RGB Line: 36,000 BPH (Krones)
- Can Line: 12,000 CPH (Sidel Simonazzi, Krones, Comaco, Dentronic, KHS)
- Keg Line: 30 kegs/hour (Lambrechts)
- Achieved significant reduction in PEL, can losses, and bottle losses
- Led installation of ECI inspection, coding, and scanning systems in RGB and Can lines
- Process Improvement & Cost Reduction
- Implemented VPO (Voyager Plant Optimization) across all maturity stages up to World Class
- Maintenance, Technology & Reliability
- Established structured Breakdown and Preventive Maintenance systems using VPO methodology
- Capacity Enhancement
- Increased Sweet Mix Plant capacity from 12 to 15 tons per shift
- Improved Vermicelli Plant output from 40 to 43 tons per day
Certification
Apprenticeship from Toyota Kirloskar Motors Pvt. Ltd., Ramanagara in the Electrician Trade with 72 %.
Personal Details
- Date Of Birth: 6th June 1994
- Address: DRG Koppalu (Village), Holalkere (Post), Arsikere (Taluk), Hassan-573126, Karnataka
Timeline
Assistant manager
Monin India Private Limited
08.2025 - Current
Assistant manager
Orkla Foods ltd
02.2022 - 08.2025
Production Executive
Carlsberg (Mysore)
04.2021 - 02.2022
Production Executive
Ab-InBev (Mysore)
08.2016 - 04.2021
Diploma - Electrical & Electronics
Rajiv Gandhi Memorial Polytechnic College
04.2001 -
Bachelor of Engineering - Electrical & Elecrtonics
Sri Jayachamarajendra College of Engineering
A Division of Toyota Kirloskar Motor - Mechatronics
Toyota Technical Training Institute