Debabrata Paul

Experience

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  B. D. R. N. Ltd

  Apr 2002 - Feb 2005

  Production Engineer

  - Responsible for conducting servicing and maintenance of machineries like Reel Machine, Separator, De-Stoners, Elevators, Conveyors, Pulverisers, Extruders etc. for preventive as well schedule maintenance.- Submitting daily inspection report of above machineries and checking the cleaning operations of raw materials before they enter to the production unit.- Monitoring the whole production procedure to achieve the target as early as possible- Ensuring proper packing of finished product and submitting daily production report.Significant Contribution- Fundamental in automating the coating systems which resulted in the increase in the production rate and quality of coating and decrease in wastage and burden of sixty workers. The same was appreciated by Plant Manager.- Maintained log book of spare parts and components required for each machine and observing machine while running for any abnormality. Show less

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  PepsiCo

  Mar 2005 - Apr 2009

  AM Production

  – Increase Line productivity from 55% to >82% in less than three years with the help of DT-5 tool.– Spearheading the preventive / predictive maintenance of machinery & equipment and improving plant uptime and reduce costs.– Focusing on identification of bottlenecks and implementation of quality & productivity initiatives in the organization.– Ensuring smooth implementation of SAP (PP Module) and SAP R/3 PP module on line compliance. Making purchasing and materials issue through SAP systems, – Production Order management strictly basis MRP results.– Implementing quality control techniques like TPM, 5S, CLITA culture in the plant.– Analysing rejections to control DMC as well as RM-PM yields.– Maintaining coding machines (Videojet ink jet, Domino Ink jet & Domino Laser Jet) in their best operational conditions. – Ensured cost savings of Rs 1.8 lakh rupees on coding cost only. Bring it down from 11 paisa to 9 paisa in the year of 2007. Also negotiated the consumables rate with Videojet which would again save another 1 lakh in 2008. Show less

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  Pepsico India Holdings Pvt Ltd.

  May 2009 - Dec 2012

  Asst Manager - Production

  – Increase productivity of both salt and liquid section by (800 to 2000 cartons /day) 150% and 75% (8 CPM to 14 CPM) respectively in less than two years (From May’09 to March’11) with the help of “DT-5 tool” and “Time & Motion Study” with zero investment.– Handling Emulsion, Blending, Repour & Extraction process in Liquid area.– Working on SAP implementation project in PWF as a Production Super User.– Working in the SAP implementation project from end to end and completed the Preparation, Fit Gap, Realisation, Cut Over & Go Live phases.– Prepared all PP related DLTs, REQs, PDDs & DDDs. – Learnt AOP preparation for production dept in 2009 & 2010 and successfully did it for 2011.– Reduced RM yield loss by 25% (~3.5 lakh INR) in 2010.– Reduced Customer complaint DPMO by 61% (65 to 24.97) in this period.– Reduced water consumption by 60% (from 1786 to 700 KL/’000 Lbs) in less than two years of time time– Deferred $178K investment by two years in salt area only as a result of productivity improvement. – Save more than 35 lakhs in two years (2010 & 2011) by doing salt carton size modification.– Ensure product availability round the year to five south Asian (India, Nepal, Bhutan, Bangladesh and Srilanka) countries. – Maintained proper GMP and ensure defect free product delivery.– Using Mapics software for production entries. – Making Site Master Plan in co ordination with volume growth plan. – Execute project of INR 200 million in Bulk storage area and completed HAZOP study for that. – Successfully completed audit for GMP, AIBI, ISO & HACCP.– Implemented TPM, 5S & CLITA culture in this plant.– Learn how to manage production complexity from Ireland Plant. Show less

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  Ruchi Soya

  Jan 2013 - Jun 2016

  Sr Production Manager

  - Controlling a team of over 150 persons and having DRs of 15.- Responsible for the overall Production, Maintenance, Quality, Packing, Dispatch, Audits, Safety & Costs.- Regular coordinating with Export & Domestic sales team and fulfill their requirements.- Coordinate among S & D, Purchase, Receiving, Stores, and Production & Dispatch for smooth operation and thus ensure not stock outs in RM, PM & FG.- Setting priority for every month and produce accordingly so that sales & production KRAs are met.- Helping the S & D team for planning their requirements in a better way.- Ensure product availability round the year to all Export as well as domestic category with all variety.- Coordinating with R & D team for new product trial runs. Bringing down the processing cost by 26% over a span of two years only without any fresh capital expenditure. • Advancing material yield from 86% to above 93% for soya granules thereby resulting in a significant improvement in cost/MT and an annual saving of around INR 2.5 Cr- Monitor daily SAP consumptions and one time BOMs correction for all products.- Handling the double screw Extruder with a wide range of soya products like Chunk, Mini Chunk, Granules, Dall Analogue, Rice Analogue and Soya Flour & Grit etc.- Handling machines like Double Screw Extruder, Nibbler, Mill, Dryer, Cooler, Bucket Elevator, Wet Milling Machines and Pneumatic Conveyors etc.- Working as an Active member of TPM - JH implementation team. Show less

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  ITC Limited

  Jul 2016 - Dec 2016

  Factory Manager

  o Was responsible for overall operation of the factory like production, maintenance, Quality, Safety, cost, statutory compliances etc.o Establish goals and objectives setting for self and team and implement accordingly. Ensure periodical review of performance against these targets / objectives of the team and provide guidance with appropriate action.o Establish effective quality control / assurance systems at factory premises to ensure consistent quality product.o Involved in making of super luxurious hand crafted chocolates like Pralines, Ganache, As You Like, and Single Origin.o Worked in a blue print project for the machine expansion plan of the luxurious unit.o Completed FMEA study for super luxurious hand crafted chocolate unit.o Worked on the new chocolate unit project for FMCG market. Show less

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  Bajaj Consumer Care

  Dec 2016 - now

  Unit Head

  Spearheading team of 500+ members for one own and six co-packer units across U.K., HP, Gujarat and Tamil Nadu with annual turnover of INR 400 Cr. and administrating operations divisions of producing Hand Sanitizer, Tooth Powders, Hair care and skin care products including Bajaj Nomarks Hand Sanitizer, Tooth Powder, Almond Drop Hair Oil, Amla Hair Oil, Bhrami Amla Hair Oil, Nomarks Anti Marks Creams, Facewashes, Face-packs and Lotionsow cost Automation project executed in FY 2023 – In Paonta Annual savings of 6 Lac against an investment of 3 lac (Unscrambler 19 ml line), In Vadodara Annual saving of 19 Lac against an investment of 1.13 Lac (Merge two Six head filling machine) etc. • Working on a project with an annual savings potential of 30L (Man & Material).• Reduced Laminate wastage by 70% over YAGO through multiple initiatives in 2019-20. • Manpower Cost Per Case (CPC) reduced by 50 % through various tools like ECRS (Eliminate –Combine – Rearrange – Simplify), Time & Motion Study, Kaizens, productivity initiatives etc.which resulted in total annual labour cost saving of more than INR 1 Cr• Total manufacturing overhead reduced 43% through various Low-Cost Automation Projects.• Part of the Central Project Team for new 3P & 2P unit induction and cost negotiations. Successfully inducted one 3P near Dehradun and one 2P near Vadodara Led SAP HANA implementation for PP module (End To End Process)• Executed a safety infra development project of 1 Cr and 3 Cr high speed new PET line in Paonta Sahib Unit• Conferred with “Greentech Environment Award & RBNQA certificate of merit” in 2019-20 for successfully leading Paonta Unit Show less