Summary
Overview
Work History
Education
Skills
Languages
Accomplishments
Timeline
Generic
RAHUL KUMAR

RAHUL KUMAR

Masaki

Summary

Results-driven Production Manager with extensive experience at Chemi Cotex Industries Ltd., specializing in project execution and process optimization. Led automation projects that decreased batch cycle time by 60 minutes, significantly improving operational efficiency. Strong background in quality control and stakeholder engagement ensures successful engineering results.

Overview

18
18
years of professional experience

Work History

Production Manager

Chemi Cotex Industries Ltd.
Dar Es Salaam
03.2022 - Current
  • Plan, prioritize, and oversee engineering projects from concept to completion.
  • Collaborate with product development, operations, and leadership teams to align engineering efforts with business goals.
  • Ensure adherence to engineering best practices, safety regulations, and industry standards.
  • Set performance goals, conduct evaluations, and support career development for engineering staff.
  • Identify process improvements, implement new tools and technologies, and drive continuous improvement.
  • Manage budgets, timelines, and resource allocation across projects.
  • Lead and manage a team of engineers across various disciplines (mechanical, electrical, software, etc.)
  • Support R&D, prototyping, and testing efforts where applicable.
  • Solve complex technical problems and guide the team through critical decision-making.
  • Monitor project risks and implement mitigation strategies.
  • Maintaining coordination with cross-functional departments for smooth functioning and accomplishing production as per customers' requirement & organizational guidelines.
  • Coordinating for engineering activities like troubleshooting & breakdown/ preventive/ shutdown maintenance for bringing down process control instruments’ downtime to a minimum level.
  • PROJECTS HANDLED IN TANZANIA CHEMI COTEX INDUSTRIES LIMITED.
  • Title: Ericson & Commissioning of Two Fryma Mixer for New Oral Plant
  • Responsibilities:
  • Worked on & finalized the plant layout as per the requirements of demand and space availability.
  • Executed end-to-end civil activities; led installation of Machinery, Electrical Systems and Drainage.
  • Conducted FAT of the Mixer and SAT within the plant for smooth execution.
  • Performed testing of each system and component to meet specifications and function correctly which included performance testing, safety testing, and quality control checks.
  • Steered implementation of the automation in manufacturing to reduce batch cycle time and eliminate manpower by 2 Nos./Shift.
  • Title: Ericson & Commissioning of Two High Speed Machine-300 UPM
  • Responsibilities:
  • Managed demand and requirement for the new machine, defined business cases.
  • Ensured availability of all necessary components, utilities, and resources for commissioning.
  • Successfully installed high-speed filling machine according to the manufacturer's specifications & guidelines; verified all mechanical, electrical, and pneumatic connections.
  • Analyzed all mechanical components such as Pumps, Valves, and Conveyors for error-free operations.
  • Interfaced with the Commissioning Team, Equipment Suppliers, and Plant Personnel to address any issues and ensured a successful start-up of high-speed filling machine.

Manager-Project

Unilever India Export Ltd.
Mumbai
02.2019 - 02.2022
  • Enhanced manufacturing hygiene standards by implementing full automation, eliminating manual intervention; all raw materials were precisely dosed in the mixer through automated processes as per batch recipes; reduced manpower per mixer by 2, which led to 60 Minute reduction in batch cycle time.
  • Implemented a CIP System and achieved product recovery of up to 95% through pigging system implementation; achieved 70% reduction in water usage through CIP implementation.
  • Expanded & automated warehouse operations to minimize non-value-added activities; implemented Cobots, Robots, and Scanning Systems, along with Racking Systems, Spiral Conveyors, Metro Conveyors, and Overhead Conveyors.
  • Managed procurement, Factory Acceptance Testing (FAT), and commissioning of high-speed machines including Acma, Norden, and Ronchi for bottle and tube lines.
  • Project Value: INR 90 Cr.

Project Planning & Execution

Unilever Sri Lanka Ltd.
05.2017 - 01.2019
  • Planning & Feasibility
  • Site selection and analysis (location, utilities, logistics)
  • Budgeting and financial forecasting
  • Risk assessment and environmental impact studies
  • Project team formation (engineering, procurement, contractors)
  • Design & Engineering
  • Plant layout design (workflow optimization, safety, space utilization)
  • Process flow diagrams (PFD) and piping/instrumentation diagrams (P&ID)
  • Equipment specification and selection
  • Utility requirement planning (power, water, air, HVAC, etc.)
  • Procurement & Vendor Management
  • Sourcing machinery, tools, and materials
  • Finalizing contracts with OEMs and suppliers
  • Coordinating delivery schedules and site logistics
  • Civil & Structural Work
  • Foundation, building, and infrastructure development
  • Electrical and mechanical utility installations
  • Safety compliance and quality inspections
  • Installation & Commissioning
  • Mechanical and electrical installation of equipment
  • Integration of automation and control systems
  • Dry runs, testing, and calibration
  • Trial production runs and performance validation
  • Handover & Ramp-Up
  • Final inspections and certification
  • Staff training and SOP development
  • Maintenance planning (PM schedules, spares inventory)
  • Gradual increase to full production capacity.
  • GREEN FIELD PROJECT

Sr. Production Executive

Hindustan Unilever Limited
Uttarakhand
05.2013 - 02.2017
  • Led erection & commissioning of CLS 2 Plant (Cream, Lotion & Shampoo) for Ericson.
  • Achieved a significant reduction in plant wastage from 7.5% to 2.5% of inner & outer laminate by implementing Sensors, Sound Alarms, and auto splicing of the Mespack Machine (240 UPM).
  • Implemented a rejection camera for the bottle line, resulting in 50% reduction in coding defects.
  • Successfully reduced changeover and sanitization time by 50% through implementation of various Kaizens.
  • Enhanced batch cycle time for Fair & Lovely Cream by 20%.

Production Executive

Hindustan Unilever Limited
Uttarakhand
02.2010 - 05.2013
  • Close-up, Pepsodent, Fair & Cream, Dove Shampoo & Lotion, Clinic Plus, Ponds Body Lotion, Sunsilk, Clear Shampoo and its variants

Production Officer

Cadbury India Ltd.
Himachal Pradesh
11.2008 - 02.2010
  • Typical Equipment Handled:
  • Mixers, grinders, slicers
  • Conveyor belts
  • Pasteurizers or sterilizers
  • Packing machines (vertical/horizontal form fill seal)
  • Metal detectors / X-ray machines
  • Cold storage units
  • Clean-in-place (CIP) systems

Production officer

Cavin Kare Pvt. Ltd.
Uttarakhand
12.2007 - 11.2008
  • Products Managed: Chik Shampoo, Nyle Shampoo, Nyle Body Lotion, Fairever Cream and Spinz Talc

Education

B.Tech. - Chemical Engineering

Institute of Engineering & Technology, M.J.P. Rohilkhand University
Bareilly, India
01.2006

Skills

  • Quality/ EHS/ Process Improvement
  • Product Design & Development
  • Stakeholder Engagement
  • Capex Estimations
  • Procurement for Engineering Equipment
  • Cross-functional Coordination
  • Industrial Safety Management
  • Project Execution & Management
  • Project management
  • Resource allocation
  • Equipment maintenance
  • Quality control
  • Safety compliance
  • Team leadership
  • Training development
  • Continuous improvement
  • Technical troubleshooting

Languages

English & Hindi

Accomplishments

  • At Hindustan Unilever Ltd., Haridwar, Uttarakhand as Production Executive
  • Recognized as Safety Champion from the Factory Manager in 2018
  • Conferred with:
  • “Trainer Award” from the HR Manager in 2017
  • “Kaizen Award” from the TPM Manager for enhancing the OEE of Mespack Machine by 7%.
  • At Cadbury India Ltd.:
  • Attained certificate for Performance of Excellence for:
  • Establishment of Project Garuda (Five Star and Gems) in 2009.
  • Safety Champion Award for project Garuda in 2009.

Timeline

Production Manager

Chemi Cotex Industries Ltd.
03.2022 - Current

Manager-Project

Unilever India Export Ltd.
02.2019 - 02.2022

Project Planning & Execution

Unilever Sri Lanka Ltd.
05.2017 - 01.2019

Sr. Production Executive

Hindustan Unilever Limited
05.2013 - 02.2017

Production Executive

Hindustan Unilever Limited
02.2010 - 05.2013

Production Officer

Cadbury India Ltd.
11.2008 - 02.2010

Production officer

Cavin Kare Pvt. Ltd.
12.2007 - 11.2008

B.Tech. - Chemical Engineering

Institute of Engineering & Technology, M.J.P. Rohilkhand University

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