SURJEET KUMAR

Mobile: +254713939785/+917087648805 Email: surjeet_jaryal@yahoo.co.in /surjeet.jaryal@gmail.com SKYPE ID:- surjeetkumarjaryal1

General Manager – Plant Operations with 18.8 years experience in Manufacturing /Operations /Maintenance/ Project Management / Manufacturing

Excellence and system implementation with leading establishments.

SYNOPSIS

Presently working with Krystalline Salt Ltd. Kenya(EAST AFRICA) as General Manager- Plant Operations from July 2015 onwards. Responsibilities includes Manufactuing Operation of Iodised Salt from Harvesting to Finished Goods production,logistics and distribution, Implementation of manufaturing Excellence techniques i.e. 5's and Kaizen programmme throughout the organisation, Compliance and administration function of 02 sites.

Worked with Rosmerta Technologies Ltd. as Plant Head at Guwahati (Assam-INDIA) for 2.9 years from Sept'12 to June'15. Responsibilities included Green Field Plant Set up, machinery selection and purchase from Netherland, erection & commissioning, manufacturing, machines maintenance,Production Planning, Logistics, Product certification by Govt. of India,Quality system management, HR & IR, Administration functions, laisoning with govt. departments.

Worked with Dharampal Satyapal Limited at Guwahati (Assam-INDIA) as Unit Head - Assistant General Manager-Production for 2.5 years from March ‘10 to Sept’12 leading 03 Plants with annual turnover of INR 500 crore handling the entire manufacturing activities included Production Planning & Control, Processing & Packaging, Plant Maintenance, Cost control,Quality Management System,GMP, Health & safety etc.

Managed manufacturing operations of 3 Units at Northeast India. 02 Units of Rajni Gandha Pan masala (Turnover: INR 450Crore) TULSI Brand Chewing Tobacco (Turnover: INR 40 Crore) , 1 Unit of CATCH Brand ready to drink beverages (Turnover: INR 10 Crore).Addition responsibilities of TQM and facilitate CIP projects for performance improvements within all manufacturing units by using Lean Six Sigma methodology. Implementation of world class manufacturing methodologies i.e. 5’s, Kaizen programme and TPM pillars,GMP and Food safety standards & act (FSSAI) in all plants.

Prior to this, I was Engineer with Moser Baer India Ltd. Greater Noida (U.P.). Over a period of 06 years (April’2004 –March’2010) I was looked after different function areas includes manufacturing, production planning, Process Improvement, six sigma projects, TPM pillars, 5’s, Kaizen Events, integrated management system etc.

Prior to above I was Executive with Twenty First Century Battery Ltd. Mohali (Punjab), from period of 03 years from March’2001–April’2004. My core activities involved are Project Management, Manufacturing, Process stabilization, Shop floor management, Wastage control,Quality system management, etc.

My career began as Junior Engineer with Magtronic Devices Pvt. Ltd. Parwanoo (H.P.) from period of 03 years from Jan’1998-Feb’2001. The main objective at this stage was to build a strong career for the future endeavors that would come my way.

AREAS OF EXPERTISE Plant Set-up/ Operations / Manufacturing Operation Excellence / TQM

A competent professional with over 18 years of qualitative experience in Manufacturing operations and Supply Chain with rich exposure to all facets of business including Annual Business Planning, Budgeting, Raw Materials & Packing Materials Planning, Procurement, Logistic, Production, Quality Control, Quality Assurance, Six Sigma Projects,TQM, Vendor Development, Process Audit, Maintenance, Project,IR, PM, HR , Administration, Dispatch and Liaisoning.

Extensive experience in handling various kinds of manufacturing processes in FMCG sector such as Refined Iodised salt proceessing & packaging, ready to drink Powder Beverages, mouth freshner, Chewing Tobacco packaging and processing lines ,High Speed Packaging machines etc.

Demonstrated excellence in heading manufacturing operations, supply chain, plant maintenance and quality management in multiple location plants.

Demonstrated excellence in QMS implementation, SOP, Specification standardization, Vendor Development & Evaluation, Process audit.

Expertise in implementing cost saving measures to achieve substantial reduction in terms of man days, production cost, raw materials, Packaging materials, Engineering spares ,indigenisation of imported material.

Implementation of Quality systems e.g. ISO 9001:2008, GMP, FSSA, 5S, Kaizen, TPM in different product areas.

Expertise in applying various manufacturing excellence initiatives such as Value stream mapping, Standardise work and visual workplace, Kanban system, SMED etc.for improving manufacturing processes, reducing process wastage, cycle time reduction, OEE Improvement, Lead Time reduction and improving customer satisfaction.

Expertise in liaisoning with Various Govt. officials(Industry Dept, Excise, Sales Tax, Factory Inspector & Pollution dept.etc.) for Plant Set-up, project expansion and subsidy.

OCCUPATIONAL CONTOUR General Manager-Operations Krystalline Salt Ltd. Malindi, Kenya (East Africa)Since July 2015 – (01 Year 03 Months)Krystalline Salt Ltd. is largest salt producer in East African Countries having 80 % export market with annual capacity of 3,00,000 MT iodised salt production.KSL is the first company in Salt work in Kenya which has the Kaizen Programme and 5's throughout all functional areas.

Responsible for overall manufacturing operation of Iodised Salt manufacturing. Operations management of 02 salt works having a total area of 2500 Hectares and producing

300,000MT of Iodised salt per year includes Salt Refinery with modern technology and Packaging lines includes Bosch,Pakona technology from india, Premier Tech. From Italy and Baler lines Raumak Brazil of 75 MT per Hours capacity.

Responsible for compliance of all statutory requirements and liason with govt. agencies. Daily and monthly MIS report to Managing Director. Restructuring the organisation manpower according to their skills, knowledge, qualification and

experience. Trained manufacturing staff in preventive maintenance activities. Implement GMP and personnel hygiene programme organisation wide. Implement Kaizen programme organisation wide. Implementation of 5's programme oranisation wide.Highlights:Holds distinction of the following functions:

o Plant and Packaging OEE improvement from 55% to 85%.o Automization of Packaging process through introducing High tech. Bagging machines, High speed

bosch machines, Raumak Baling machines and palletization.o 33 % energy and 50 % manpower cost reduction.o Mechanization of Salt Harvesting to reduce 50 % cost of production.o Cycle time reduction of 500g packaging lines to increase productivity from 120 packets to 140

packets per minute.o Preventive maintenance system implementation in plant and packaging section.o Mechanization of Salt harvesting from fields.o Streamline Despatch activities of finished goods to direct customers and our warehouses.o Implement Model for Purchase of Firewood and Inter unit transfer of raw salt.

Plant Head -Rosmerta Technologies Ltd. Guwahati (Assam) Sept’ 2012- June,2015 (02 Years 09 months)

Rosmerta Technologies Ltd is a group of companies manufacture automotive componenets such as speed governors, vehicle tracking systems, auto-fare meters and High Security Number Plates(HSRP). I was leading the High Security Registration Plates (HSRP) business segment.

Key Result Areas: Responsible for set up of Green field plant for HSRP project including land acquisition, certification with

state Govt.Construction of building, machinery selection,erection and commisioning of machines and certification of product with regulatory bodies of Govt. of India.

Responsible for overall manufacturing operation activities of High Security Registration Plates. Responsible for overall manufacturing operation activities in terms of productivity, efficiency, quality,

capacity, safety, cost control. Looking after product COP and product approval process from ARAI & CRRI for HSRP. Ensuring the alignment of factory targets in line with corporate business objective through BSC and set

KRA/KPI. Accountable for delivering safety, health & environment targets and developing safety culture in plant.Highlights: Holds distinction of the following functions:

o Set-up and running of green field projects for HSRP manufacturing with a total investment of Rs. 200 million.

o Erection and commissioning of Netherland based HSRP production lines including pneumatic and hydraulic transfer presses, hologram stamping units and lamination units,Lasering Machines, DG Sets, Compressors and Air Dryer and Centralised Air condition.

o Indigenization of raw materials i.e. Aluminium coils, Chromium Hologram for manufacturing High Security Registration Plates.

Recognized for first automated PLC based Plant set-up for HSRP manufacturing in India with capacity of 30 million plates per annum.

Appreciated for successful running of low cost retro-reflective sheeting for HSRP resulting in a reduction of raw material cost by 30%.

Unit Head - Assistant General Manager-ProductionDharampal Satyapal Limited, Guwahati (Assam) - March 2010- Sept’ 2012 (02 Year 06 Months)

Dharampal Satyapal Group (DS Group) is INR 3200 crore rapidly growing multi-diversified conglomerate that has a strong presence in sectors such as Food & Beverage, Mouth Fresheners, Tobacco & related products, Packaging, Dairy, Agro forestry, Rubber Thread, Hospitality and Infrastructure with Steel, Cement and Power. Some of the popular brands owned by the Group today are – Dairy Max, Catch Spring water, Catch flavoured water, Catch mix –to-drink( Zalzeera, Nimbu Paani,Piyoz), Catch Spices, Pass Pass,Chingles, Rajnigandha- a non tobacco Pan Masala, Baba, Tulsi etc.

Unit Head with T&R Division

Highlights Oversaw overall manufacturing of 03 units i.e. Pan-masala, Zarda, NimbuPani & Jaljeera (mix to drink

beverage) for ensuring product availability as per the market demand and meeting the budgeted volume.

Handled activities pertaining to multiple plant operations. Looked after various activities of FMCG product processing and packaging including production planning, RM

/PM planning, quality management, machine maintenance, store management and logistics. Streamlining new process concepts for production optimization, yield improvement and adopting

various cost reduction techniques. Handled the erection & commission of Sanko Japanese Packaging Lines for ready to drink beverages,

mouth fresheners, pan masala and tobacco packaging. Successfully carried out the following activities:

o Led technological changes for packaging process transformation from 200 pouch per minute to 750 pouch per minute on Japanese packaging lines.

o Facilitated process stabilization of paper laminate packaging for all variants of Rajnigandha Pan Masala, Tulsi Zarda after ban on plastic laminate packaging.

o Reviewed and upgrading of the documented system of ISO 9001: 2008 (QMS) according to technological changes in manufacturing process.

o Planned various audits like internal, process and GMP audit as well as implemented measure for effectiveness of audit.

o Developed road map for Kaizen Programme and implementation in all plants of DSL, Guwahati. Led, implemented, monitored and maintained Food Safety Management System (FSSA), ISO 9001: 2008

QMS in all plants. Conducted audits & gap analysis for Quality Management System. Held responsibility of facilitating quality improvements and cost reduction projects within all

manufacturing units by using Lean tools and Six Sigma Methodology. Ensured maintenance of an effective and efficient safety & environmental system in all units. Carried out execution of LEAN manufacturing principles as well as LEAN tools (safety first, suggestion

scheme, problem solving, visual management, 5 minutes meeting, kanban, SMED, 5S, Poka- Yoke, Standardized work, one piece flow in all units.

Engineer - Moser Baer India Limited, Greater NoidaApril 2004 –March 2010 (06 years)The concern is the world’s largest CD & DVD (optical media) manufacturing plant with an annual turnover worth INR 2000 Crores & a market share of 20% in the optical media. MBIL is the major OEM for Sony, Philips, MKM,TDK,Imation and HP world’s leading brand in optical media.

Key Result Areas :-

Ensuring optimum utilization of resources (Man, Material, Machines) available for production. Ensure achieving targeted productivity with targeted yield on lines. Managed 18 DVD-R lines producing 4.75 lacs discs per day. Overseeing that allotted and designated tasks are carried out in time by strictly following safety, quality

and production norms. Provide regular training to subordinates to use tools such as cause & effect analysis & DEMAIC to find

the root cause and solve the problems. Maintenance of automated PLC controlled lines includes pneumatics, Pick & Place units. Responsible for implementation of world class manufacturing practices i.e. 5’s, Kaizen, TPM, Six sigma

projects on shop floor. Responsible for Process control, quality control operations and finished product inspection. Establishing Quality Management Plans across various processes to eliminate downgrading levels and

ensure high quality standards at all the stages of production. Undertaking customer audits / visits and all special testing, data presentation while visit. Responsible for review, modify and maintain IMS (Integrated Management Systems) documents.

Completed six sigma projects on reduction in customer complaints, cycle time reduction, Polycarbonate wastage control and visual downgrading PPM improvement.

Executive - Twenty First Century Battery Ltd., Mohali (Punjab) March2001-April2004 ( 03 Years & 01 month)

TWENTY FIRST CENTURY BATTERY LIMITED manufactures advanced Plastic Lithium-ion Batteries with technology licensed from Telcordia Technologies Inc. (formerly Bellcore) of U. S. A. It manufactures Plastic Lithium-ion Rechargeable Batteries.Highlights Machinery installation & modification of machines for manufacturing batteries as per design. Responsible for optimising process parameters to achieve targeted yield. Production planning and control. Ensuring the Quality of raw material/packaging material/finished goods, by putting quality checks

during incoming material inspection/in process inspection and final inspection. Responsible for analysis of defects using QC tools and making action plans. To conduct internal audit and prepare CAPA for non-conformities. Implementation of SPC, 5’s and Kaizen activities on shop floor to improve work culture and employees

motivation.Junior Engineer - Magtronic Devices Pvt. Ltd.Parwanoo (H.P.) January 1998-February 2001( 03 Years & 01 month)

M/S MAGTRONIC DEVICES Pvt. Ltd. (a group company of ALLEN ELECTRONICS) is an ISO: 9002 company manufactures Audio Magnetic Sound Heads, collaboration with SANKYO SIEKI SINGAPORE. Highlights Responsible for commissioning of assembly lines for stereo head core assembly. Responsible for the operation of assembly lines and maintenance. Responsible for in process quality control and maintaining system compliances. Manpower and Material management as per production plan. Responsible for maintaining 5’s and Quality Circle activities on shop floor.

WORKSHOP ATTENDED Six sigma Green Belt certification from Indian Statistical Institute, New Delhi. Certified ISO 9001:2008 Internal Auditor from Bureau Veritas Certification (formerly BVQI). Successfully attended a workshop on Lean Manufacturing, TPM, 5-S, Kaizen, Waste management, SPC,

7-Quality Tools, DMAIC, QMS, GMP &IMS (Integrated Management System)

EDUCATION

MBA in Operations Management from IGNOU, New Delhi in 2010. B.E. in Industrial Engg. from IIIE, Navi Mumbai in 2003. Diploma in Instrumentation Engg. from H.P. Takniki Siksha Board Dharamshala in 1997. 10th from H.P. Takniki Siksha Board, Dharamshala H.P. in 1994.

CERTIFICATION Certified with:

o ISO 9001:2008 Internal Auditor from Bureau Veritas Certification (formerly BVQI) in 2011o Six Sigma Green Belt Certification from Indian Statistical Institute, New Delhi in 2009

PERSONAL DETAILSDate of Birth: 25th June, 1978Permanent Address: S/o Shri Parmodh Singh, Village Nagni, P.O.Moondhi, Tehsil Palampur, Kangra-176092,

Himachal PradeshPresent Address: Krystalline Salt Ltd. Gongoni, Malindi, Kilifi County, Kenya.Languages Known: Hindi, English and Assamese