Umesh Kalra

Profile: Responsible for management of two Manufacturing plants for Nutraceutical with Key focus on Capability Expansion in addition to Plant KPI.

Key Achievement:

• Successfully Improved the plant capability by 80%..
• Improved the Manpower Productivity by 11% with Zero investment .
• Initiated project for improvement in Operations cost by 30%
• Successfully established all New Products

Profile: Responsible for Plant management with a team of unionized work force of 1000 , leading the key agenda of Safety, Sustainability, Quality & food safety, Operation Cost, Volume delivery & Industrial relation s.

Key Achievements:

• Successfully led two Long term settlement with Union without any business interruption
• Refrigeration savings of 1.1 million INR per year.
• ETP Process stabilization of USBAR, saving of 0.7 M INR per year.
• Boiler development of Alternate fuel, saving of 5 M INR per year.
• Successfully executed global productivity improvement project,.
• Improved plant OEE by 5% by optimizing planning Process.
• Successfully improved quality of milk by improving storage temp by re-engineering.
• Improve the efficacy of Ghee Manufacturing & granulation process, resulted in reduction of complaints.

Profile : Responsible for Operation Management of the plant, leading a team of 4300 Workmen (at peak) to achieve Volume, Asset management, Safety, Quality and Cost objectives for the Organization.

Key Achievements:

• Lead role in commissioning, installing & stabilizing the new Manufacturing site & Managed to lead two plants simultaneously.
• Managed to cater to increase in volume demand by 5 fold with various project activities related to expansion, quality improvements, etc.
• Worked closely with HR and worker's union, in closing the wage agreement in record time.
• Lead projects for new product/formats/flavors development and launches.
• Executed various projects related to Supply chain including inventory reduction, inventory flow, WIP inventory process, Pills warehouse management, etc.
• Initiated various projects related to efficiency improvement in various directions of material, manpower and energy usages.
• Planned and executed, skill development programs for asset management team.
• Planned and executed start-up & Stabilization of third party manufacturing as part of manufacturing strategy.

Profile: Responsible for Production management for the plant, with key agenda of volume delivery, safety quality & production planning, usages variance managed executive staff of 06 & 750 shop floor members,handled Budget & Capacity planning for three plants.

Key Achievements:

• Handled International assignment of setting up of Hard Boiled Candy line (11 ton/day) at Bangladesh.
• Handling of 4 deposited , 1 hard boiled candy , 2 boiled candy and 02 gum lines.
• Enhanced the Capacity of Deposited line by 5%, through innovative idea of Shape Change.
• Started commercial production for various new Product Developments (Happy dent Wave, Sploosh, Center fruit, Cr Fills, Blister packs).
• Executed the commissioning of new projects as Forming line APV beakers continues Microfilm cookers, Depositors, Coating Pans , Sugar Dissolvers.
• Significantly reduced packing materials loss from 3% to 1.2% through optimum controls.

Profile : Responsible for the shift management & in-charge of production planning.

Key Achievements:

• Saved electricity worth one million INR in year 1999-2000 through controlling & optimizing the use of refrigeration.
• Increased productivity in terms of manpower utilization by 4%, reduced losses to 1.25%, by using flushing of tanks & freezers.

Key Achievements: Developed recipe & procedures for new Acidophilus based refreshment drink from whey.