Summary
Overview
Work History
Education
Skills
Certification
Languages
Affiliations
Experinced Processing Machines
Timeline
Generic

Shivaprasad Hanji

Bangalore

Summary

Accomplished operations and manufacturing excellence professional with 12+ years of proven experience driving process optimization, cost reduction, quality improvement, and large-scale project implementation across FMCG and food manufacturing industries. Skilled in TPM, Lean, Six Sigma, Industry 4.0, and supply chain optimization, with a strong track record of delivering sustainable cost savings, efficiency improvements, and capability building across multi-plant operations. Recognized for building high-performance teams, leading transformation projects, and ensuring compliance with global safety and quality standards. Detail-oriented Assistant Manager offers more than extensive progressive record of accomplishment in leadership roles. Establishes clear guidelines and enforces consistent policies to keep staff satisfied and on-target to achieve important objectives. Excellent relationship-building, multitasking, and decision-making skills.

Overview

12
12
years of professional experience
1
1
Certification

Work History

Assistant Manager – Manufacturing Excellence

ITC Ltd.
Bangalore
03.2025 - Current
  • Driving company-wide Manufacturing Excellence systems across 4 mega factories.
  • Implemented a digital portal for monitoring excellence KPIs and initiatives.
  • Identified and executed improvement projects, achieving 5% cost reduction in total conversion and material cost.
  • Developed capability-building programs and training sessions for factory teams.
  • Partnered with PwC to deliver INR 200M projected annual savings through cost optimization projects.
  • Coordinated team schedules to optimize workflow and resource allocation.
  • Supported management in developing training programs for new employees.
  • Facilitated communication between departments to enhance operational efficiency.

Manufacturing Manager

Orkla India
Bangalore
03.2024 - 03.2025
  • Managed end-to-end operations for RTE, RTD, and confectionery production plants.
  • Achieved PQCDSM targets across all production units.
  • Designed and implemented in-house RM cutting system, saving INR 7.2M annually.
  • Led capacity expansion of RTE sweets line from 2MT/shift to 4MT/shift with minimal capex investment.
  • Oversaw daily manufacturing operations and ensured compliance with safety regulations.

Senior Executive – Manufacturing Excellence

ITC Ltd.
Malur
03.2020 - 03.2024
  • Led manufacturing excellence initiatives in a high-capacity plant (130+ MT/day production, 1000+ manpower).
  • Delivered 30+ CI projects, saving INR 24M+ across FY21 –FY23.
  • Spearheaded Industry 4.0 implementation, streamlining end-to-end production processes.
  • Facilitated Kaizen programs, 5S, TPM, QCFI projects, and CII competitions.
  • Implemented JH pillar methodology (CLIT, RCA, MTBF/MTTR tracking) and certified as TPM (JH Pillar) Facilitator by CII.
  • Developed and mentored operator-led small circle projects; 50+ operators participated in QCFI competitions.
  • Led cross-functional teams to enhance project execution and drive strategic initiatives.

Executive – Manufacturing

ITC Ltd.
Trichy
05.2018 - 01.2020
  • Commissioned new Noodle and Potato Chips production lines in a greenfield project.
  • Improved line performance, saving INR 12M through early-stage R MPM variance control.
  • Enhanced noodle line capacity from 52MT/day to 55MT/day, achieving INR 45M annual savings.
  • Anchored TPM initiatives including Video OPLs, AM, and Visual Management for rapid operator capability building.

Production Officer

Nestlé India
Goa
03.2016 - 05.2018
  • Supervised 120+ manpower/shift across process, packaging, and export production lines.
  • Improved laminate yield from 96% to 98%, and reduced steam loss by 300 kg/hr.
  • Ensured compliance with OPRP, CCP, GMP, GHK, and export quality standards (US, UK, AUS, NZ).
  • Drove DMAIC, GSTD, and continuous improvement projects to enhance operational efficiency.

Executive – Manufacturing / TPM

Hindustan Coca-Cola Beverages Pvt. Ltd.
Hyderabad
06.2013 - 02.2016
  • Core team member in winning the Max PET Award and Indian Manufacturing Excellence Award (ET, 2014).
  • Served as Deputy Chairman – Jishu Hozen Pillar, successfully challenging JIPM Excellence Award (Category A).
  • Commissioned 450BPM PET line, achieving 88% OEE within 2 days of installation.
  • Reduced changeover time from 120 mins to 65 mins using ECRS methodology.
  • Authored a 'Know-Why Book' with 150+ sheets, replicated across HCCB plants.
  • Led Kaizen competitions (1st Prize, 2014 & 2015), TPM training initiatives, and SOP standardization for new lines.

Education

B.E. - Mechanical Engineering

BVBCET
Hubli
01.2013

Skills

  • Manufacturing excellence
  • Production and people management
  • Continuous improvement
  • TPM Pillars Deployment
  • Six Sigma - DMAIC
  • Production planning
  • Loss cost matrix
  • Supply chain management
  • Materials management
  • Food safety management systems
  • Capability development
  • Data Visualization - Power BI

Certification

  • Six Sigma Black Belt – ISI Pune
  • TPM Facilitator Training – CII TPM Club
  • 7-Step Problem Solving Methodology
  • 5S Auditor Certification
  • KHS Academy – RGB & PET Production Machines

Languages

  • Kannada
  • English
  • Hindi
  • Tamil
  • Telugu

Affiliations

  • Won national-level kaizen competition organized by CII, awarded as 'Champions of Champions' under restorative category
  • Lead Assesemnt from NAMC got Gold Award for the Factory by IRIM- "International Research Institute for Manufacturing "

Experinced Processing Machines

  • PET and GlassBottling Line
  • Noodle Manufacturing Line (Mixer , Rolling , Frying)
  • Packaging Machines - VFM , HPM.
  • Retorting System .
  • Can Lines

Timeline

Assistant Manager – Manufacturing Excellence

ITC Ltd.
03.2025 - Current

Manufacturing Manager

Orkla India
03.2024 - 03.2025

Senior Executive – Manufacturing Excellence

ITC Ltd.
03.2020 - 03.2024

Executive – Manufacturing

ITC Ltd.
05.2018 - 01.2020

Production Officer

Nestlé India
03.2016 - 05.2018

Executive – Manufacturing / TPM

Hindustan Coca-Cola Beverages Pvt. Ltd.
06.2013 - 02.2016

B.E. - Mechanical Engineering

BVBCET

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Shivaprasad Hanji