Kalyansundaram K.

Experience

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  Shubham Pack

  May 2005 - Jul 2007

  Service Engineer

  Installation and Commissioning.

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  Shubham Pack

  Jul 2010 - Oct 2011

  Production Engineer
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  AVT Beverages

  Nov 2011 - Nov 2014

  Senior Engineer - Plant Maintenance

  Maintenance:Hands of experience in Maintenance and troubleshooting of packing machines like single and multi track of ( Bosch ,Meshpack, Hassia,Rovema, Rollentainers, Imar , Shubham pack,Akash pack )Experience in different types powder blending process machines Prepare PM plan for all packing lines and equipments and complete 100% compliance. Daily plant round and ensure all lines and equipments are running condition Tracking line wise OEE Tracking machine down time and doing RCA for major breakdown and CAPA in place.Planning Machine critical spares and local vendor development for critical spares Ensure all weigh machine calibration compliance Show less

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  The Vanity Case Group of Companies

  Nov 2014 - Nov 2015

  Assistant Manager Production

  Production : Planning and proper execution of man, materials and machines.Prepare production planning for packing line in primary packaging Manpower planning for all 3 shifts and allocate work accordinglyResponsible for maintenance of packaging machines and equipments Responsible for achieve OEE of all 12 packing lines of detergent packaging.Attending daily tier meeting and discussed about previous day report Implementation of 5s , TPM , in floor and trained up operators and supervisor for the same Coordinate internal meetings of New Projects and review of new projects. Show less

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  Abbott

  Dec 2015 - Aug 2019

  Front Line Leader -Manufacturing

  Production :1.Look after Dry Blending process ,Primary packaging (Pouch and Sachet Filler lines) ,secondary Packing ,maintenance Activities.Key deliverables: Achieving production target as per PSA ,Achieve Dry Mix Blender , Pouch and Sachet Lines OEE Target ,yield Improvement, zero leak approach in pouch and sachet lines , Perfect Batch target , PM compliance ,produce quality products, ensure safety, , manpower planning & allocation, engaged with Associate, monthly production volume compliance. Track, trend and continuously improve budgetary performance for yield improvement, overtime (OT), Overall Equipment Effectiveness (OEE), SIC for production (kg /Hour) and Scrap and Cost Improvement Projects (CIP).Monitoring & Control of CCPs (Critical control points).Analyze line wise RM /PM wastages and take necessary corrective action to control wastage.Prepare and implementation of Operator standard work (OSW), Standard operation procedure (SOP), one-point lesson (OPL) and Work instruction for manufacturing operations.Trained up associate for doing simple RCA, metrics,Area ownership and Cross matrix training conducting for associates Responsible for achieving packaging schedule adherence (PSA), Manufacturing schedule performance (MSP) Investigating problems facing in production and finding appropriate solutions to them.Doing A3 tool and Simple RCA for Machine breakdown, Quality defect in production related consumer complaints and CAPA implementation Gembh walk down during shift operations to ensure safety, quality, production and people in shop floor. Validation performance of IQ, OQ, and PQ for machine and equipment’s.Blending /Packing cleaning time reduction. To ensure the implementation of lean manufacturing tools , 5’s, SMED,Pokeyoke,TPM,six sigma,FMEA and kaizen. ISO 9001:2008 / ISO 22000 / ISO 9000:2000 / AQR audit team member Aware of EHS /HACCP /FSSAI / CII /BRC /GMP / GDP Show less

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  Cargill

  Aug 2019 - Sept 2020

  Manufacturing Manager

  PRODUCTION: -• Overseeing Production operations of Powder and Liquid section.• Ensure monthly department KPI goals are achieved.• Fully responsible for day to day production operation of powder and liquid section. • Ensuring Daily production targets are achieved as per as scheduled production plan.• Closely working with PPC team to do effective monthly production planning and reduce CIP hours.• Focusing line OEE, Yield, Throughput, Breakdown, Scrap of powder and liquid section.• Coordination with operational excellence team for continuous improvements at manufacturing area. • Preparing plant MRM report for monthly review meeting.• Focusing on cost improvement projects at both powder and liquid section.• Analysis of production data for productivity improvement at lines. • Review with progress of work, manpower management, preparation of reports on periodical basis regarding production losses and other parameters.• Coordinate other functions like Safety, Quality, Materials and Engineering.• Supervising the work of down the line and organizing relevant training sessions.• Ensuring that health and safety regulations are met.• Estimating, negotiating and agreeing budgets and timescales with clients.• Drive continues improvement in production and process by implementation through new ideas. • Identifying areas of quality failures and taking steps to rectify the system wide preventive and corrective actions to avoid the reoccurrences.• Providing adequate Training for Quality improvements. Food safety, HACCP, Hygiene, GMP for all plant personal.• Played an active role in implementing Lean Tools, HACCP,5S, Kaizen, TPM ,FMEA,HIRA.• ISO 9001:2015 / ISO 22000 / ISO 9000:2000 / Cargill internal audit.• Aware of EHS /HACCP /FSSAI /FAMI-QS /FSMS/ CII /GMP / GDP /IMEA.• Experience to face Annual Quality and EHS Audit. Show less

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  Khanal Foods Pvt Ltd.

  May 2022 - Dec 2023

  Production Manager

  • Look after Production/Maintenance planning and Management, Inventory Control (RM, PM and FG). • Closely working with PPC team to carry out effective monthly production planning & Scheduling for Month.• Focusing on line OEE, Productivity Kg/Manhr, Conversion Cost, Yield, Throughput, Breakdown and Scrap. • Coordination with procurement team for RM/PM connectivity to fulfill as per rolling plan.• Developing and strategizing department objectives to achieve business goals.• Coordination with Sales, Fulfill and replenishment team for timely dispatch as per plan.• Prepare and implement SOP, OSW and OPL at the work floor for easy understanding of the work.• Ensuring Daily production targets are achieved as per scheduled production plan.• Setting monthly and annual goals, budgets and developing organizational plan for achieve the goals. • Work with QA team, in case of any customer complaints and proactively identify & take improvement actions to reduce customer complaints. Prepare RCA and CAPA for customer complaints.• Trained the Supervisors and Associates to do the Simple RCA, A3 Tool for Machine breakdown and Quality defects.• Coordinating with operational excellence team for continuous improvements at Plant level.• Ensure monthly department KPI goals are achieved, Preparing plant MRM report.• Closely working with Capex on timely execution of the project.• Coordinate with M&E team to do IQ / OQ & PQ tests for new packing machine and equipment in plant as per protocol.• Ensure supervisory staff & workmen are well trained. Continually improve their skills and competence levels.• Drive continues improvement in production and process area by implementing new ideas. • Experience and implementation of Lean tools like 5s, Kaizen, TPM, OEE, Poke Yoke, RCA, VSM, JIT, FMEA, HIRA.• ISO 9001:2015 / ISO 22000 / Abbott AQR Internal audit / Cargill internal audit.• Aware of EHS /HACCP /FSSAI /FAMI-QS /FSMS/GMP /GDP/EIC/BRC Show less

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  Licious

  Dec 2023 - now

  Operations Manager