Sujay Pradhan

Experience

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  Godrej & Boyce Mfg. Co. Ltd.

  Nov 2010 - Jun 2014

  Assistant Manager - Maintenance

  ● Managing spares by system of bin cards, implemented Visual Control System and executing cycle counting & ordering● Analysis of breakdowns, calculation of MTBF and MTTR and planning corrective & preventive actions through four quadrant chart● Successfully cleared the external audit in 2014 and contributed in achieving TPM excellence award for the plant● Implemented IMS and successfully cleared ISO 9001, 14001 & 18001 external audits. Also, contributed in winning the EB Business Excellence award Show less

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  General Mills

  Jun 2014 - Aug 2019

  Sr. Engineer - C&FS Platform

  ● Achieved $ 380K savings and reduced 6015 hours through PM balancing & frequency optimization across 8 Pillsbury lines● Achieved savings $40K / year by drastically reducing the failure of running wheels of Freezer on French toast line● Savings of 4000 man hrs by developing automated excel tool to see line-wise losses, equipment performance metrics ● Achieved $46K savings in part cost and 329 hrs of uptime by analysing & bench-marking parts used across Yoplait & Pillsbury lines. ● Developed process of remote planning & scheduling system for YoplaitMaximo(CMMS) Business Lead- Maintenance● Successfully supported version upgrade to 7.6 with end-to-end testing of maintenance modules & implementation at 2 new sites in Canada. ● Developed business lead role by creating job task analysis(JTA) document and designing operational metrics ● Process mapping & documentation of Maximo implementation at new site by integrating inputs from teams along with resources, cost and timelines Show less

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  Kansai Nerolac Paints Ltd

  Sept 2019 - now

  Assistant Manager- Central Engineering

  MRO Inventory● Analysing MRO inventory across 8 plants, developed categorisation matrix & devised overall inventory optimisation strategy● Achieved inventory reduction target of Rs 210 lac for fast moving and non-moving inventory● Planned for Rs 64 lac reduction of critical & slow moving inventory through identification of common spares. Also, implemented process flow in SAP● Analysed inventory & identified parts for transitioning from physical to digital inventory to improve lead time & achieve cost efficiency (Pilot WIP)● Achieved cost avoidance of Rs 35 lac by analysing spare codes for duplicity & carrying out inventory consolidation● Re-engineered material codification process to improve part code search and description building to reduce duplicity & avoid inventory build upRepair & Maintenance● Identified spares indigenisation opportunity of Rs 68 lac by analysing import spares procurement based on multiple criteria● Achieved repairs cost reduction of Rs 50 lac through analysis of repair activities across plants for renegotiation or rate contracts with vendors● Bench-marking spares spend to identify blocks with high spend. Implemented IIOT based CBM system to achieve 20% spares spend reduction● Developed Zero based budgeting for spares by analysing spares consumption● Released 178 KL paint capacity by PM efficiency improvement, standardisation across plants through advanced maintenance tools usage● Identified AMC cost reduction opportunities worth Rs 22 lac in utility category by analysing & bench-marking spend across plants● Documented process flow for spares spend adherence to budget with swim-lane map & developed same in SAP to ensure control● Re-engineered the Capex process to reduce approval time by 1 week.● Created de-carbonization road-map by analysing power & fuel consumption across all plants & subsidiaries & forecasting consumption basis volumeMIS reporting● Reporting to management on KPI’s, CAPEX project, SPC & SFC Show less