1. RAJENDRA A DHAGE
Contact: 09822034269 / 09028019869 / 02532410896
E-Mail: rajeshdhage@rediffmail.com / rajeshdhage75@gmail.com
Plant Head Operations
Production Operations ~ Quality Assurance ~ Material Management ~ Plant Operations ~ Cost Control
A dedicated analyst, proficient in running successful method-oriented production operations & taking initiatives for business
excellence through process improvement
Seeking challenging assignments in Plant Operations with an organization of repute in Manufacturing sector
PROFILE SUMMARY
 A dynamic professional with over 19 years of experience in:
Production Operations Quality Assurance Material Management
Plant Operations Cost Control Team Management
Strategic Planning Liaison & Coordination Process Improvement
Human Resource Finance Plant Shifting and Commissioning
 Skilled in finalizing the specifications of materials, establishing quality & quantity limits for effective inventory
control and reducing wastages
 Gained significant experience in working with various industries including Industrial Products, Heavy Machinery,
Capacitors, Electronics, Chemical, Extrusion process Of Electrodes, Annealing, Automotive Forged and PAINTED
Parts etc.
 Sound understating of Lean Engineering, TPM/TQM, various Quality Tools, , well versed with Production function,
Kaizen ,VSM & Productivity improvement technique
 Adroit in executing cost saving techniques / measures & modifications to achieve substantial reduction in O&M
expenditures and work within the budget
 Skilled in developing and executing high-level strategies, make high-stakes decisions and combat mission-critical business
challenges for effective results
 A result – oriented individual with excellent planning & problem solving skills
 Adept with cost control mechanism, Improving P & L bottom line.
 Handled plant having manpower more than 800 nos.
 Experience in wage agreement with CITU operated union.
 Worked under pressure of daily targets achievement of automotive customer Bajaj with a concept of JIT concept.
 Had an edge on strategic planning and Goal setting.
CORE COMPETENCIES
Plant Management( Total 3.0 years)
 Spearheading plant activities involving working out various requirements & monitoring overall plant operations for
ensuring timely completion
 Monitoring the activity at sites and undertaking review of schedule, ensuring cost control within budget, planning for cash
flow requirements, Implementing cost controlling mechanism etc.
 Gap analysis ,Capacity planning
Production Operations (total 17.0 years in continuous process plant)
 Formulating & executing the production and manpower schedules / plans for smooth execution of projects at within
time & cost parameters
 Coordinating with various departments including material department for ensuring accomplishment of daily & monthly
production targets; ensuring cost reduction by implementing new techniques and working on productivity improvement
 Had experience in Hydraulic and pneumatic press , Sheet metal industries.

2. Quality Assurance & Control(Total 3.0 years)
 Implementing quality tools to ensure process capability per specification requirements, monitoring by control plan
preparing and implementing improvement & corrective action plan
 Developing quality plans & ensuring quality assurance for equipment in manufacturing by inspection control in various
stages, process control as per standard
Operations & Maintenance(total 6 years)
 Ensuring execution of preventive maintenance of Power Plants, including schedules / shutdown maintenance to ensure
trouble-free and seamless plant operations
 Effectuating predictive, preventive & breakdown maintenance schedules of plant assets; conducting periodic checks to
ensure performance of various equipment
 Liasoning with government officials in respect with factory acts and statutory requirements.
ORGANIZATIONAL EXPERIENCE
Since Aug14 Working in BLG-Parikh Aurangabad as a Plant Head.
Group Turnover is 1000 Cores. Unit Turnover is 60 corers.
 Organization Type: Automobile, Major Supplier of Bajaj Auto, Mercedes Benz, FIAT And Tata.
Current Portfolio:
 I am responsible for plant operation in all aspects. Playing key role in improving plant efficiency,
responsible for improving bottom line. Responsible for improving business profitability. Increase
business volume.
 Working as a TPM facilitators since one year. Played key role in TPM implementation.
 Well verse with Bajaj Auto Ltd operating system as it is a key customer.
 Handling independently the Plant with benchmark productivity systems.
 Handling all legal and Government requirement related to Sales tax, Exise, Factory Acts.
 Responsible for 2 wheeler/3 wheeler/4 Wheeler various assemblies, inclusive of LPG/CNG/Petrol /diesel
models.
 Responsible for Planning, coordination, Training , Motivating Team, Improving Skill .
 Responsible for Budgeting ,controlling the same, ROI, Gap analysis.
 Handling RFQ’S and costing.
 Handling Union activities.
 Size of Plant: 400 workmen, 36 (Executives, Managers).
MAJOR ACHEIEVEMENT:
 Increased profitability from 9.2 % to 16.21 % within 6 months.
 Converted the productivity from wage rate to piece rate successfully.
 Transform the plant to zero accident.
 Resolved HR issues of BLGP employee & increased their morale.
 Converted the Unorganised plant into organised way, systematised all the operations.
 I was appointed as Best leader amongst 5 plant heads , and nominated our German magazine which was
released in Dec-14. And in June15
 Efficiently transferred the plant and machinery to new location without disturbing customer’s requirement.
 Handled all legal formalities of new plants independently.
 Raised the companies Brand to a high level from Customers point of View.
 Working as a TPM facilitator within a year implemented 5 pillars of TPM.
 Since last 9 month Zero line loss at Customer end , Stand second in BAL vendor ratings
 Implemented ISO9000, EMS14001 within 9 months
From Sep’12 to August 14 worked in Graphite India Ltd., Satpur, Nashik as Senior Manager Operations
Plant Turnover: 600 Corers
Team Size: 1 Manager Production, 1 Dy. Manager - Maintenance, 1 Asst. Manger Process, 24 Engineers/16 Staff/116 Workmen
Role:
 Managing the department having capacity of producing 4000mt capacity per month with Task force of 159 nos.
 Handling various KRA’s In line with top management objectives
 Overseeing overall responsibilities of improving bottom line, responsible for cost cutting and generating profit for the unit

3.  Heading the overall Production/Quality/Maintenance/Engineering activities
Jan’08 - Sep’12 TDK EPC (Epcos India Pvt. Ltd.) as Manager Production
Team Size: 350 Operators (Unionized) and 26 Engineers
Foreign Exposure: Availed training for Line Balancing in Spain Malaga
Role:
 Handled production unit having capacity of 24 million pieces/month (TO of 7 Bill Euro)
 Managed plant consisting of 250 + special purpose machines
 Coordinated with different government officials including Factory Inspectors, Municipal Corporation, MSEB & MPCB
Highlights:
 Successfully:
o Improved EBIT from 9% to 13% within 12 months
o Reduced material input cost by 6 % through import substitution
o Handled union agreement for three years period tactfully, where monthly rise was 15% in pieces
 Deftly managed production within 3 months from 4.6 Million to 5.2 Million /Week
 Skillfully implemented TPM & increased OEE from 45% to 53% in 6 months in last year 2011 and till today it is increased
to 66% Jun2012
 Played a vital role in:
o Reducing Scrap from 9.3% to 6.6% within six months
o Implementing concept of VSM & reduced the non value added time by 20%
o Setting all the EMS documents & system for ISO14001 also trained in TS16469.
o Handling factory emergencies and designated as Chief Control Officer for Nasik Plant
 Resourcefully handled responsibility of QA parallel with Operations Team
Apr’96 – Dec’07 Graphite India Ltd. As Dy. Manager Operation
Role:
 Managed 3 Production Shops with task force of 90 Operators & 12 Engineers with manufacturing capacity of 6000Mt
electrodes per month includes Extrusion, Heat Treatment, and Graphitization.
 Headed cost of poor quality, design of experiments, TS audits, 8 d techniques, different quality tools
 Responsible for ensuring Maintenance, Production, Quality Assurance, Planning with approving authorities and
concerned department
 Handled utilities, PLC Operated Kilns, Pneumatics', Hydraulics, Ceramics, etc.
 Resolved issues related to maintenance and services
 Prepared many innovative & improvement ideas as the member of Kaizen (continues improvement) so that the team
could work smoothly
Highlights:
 Deftly implemented TPM, VSM, EMS14001, Zero Defects, KAIZEN, etc.
 Successfully established department (April2007) within 4.5 months with quality & production targets
 Served as a member of the Core-Team Member of ISO 14001
 Skillfully implemented the EMS System within 3 months
 Played a vital role in redesigning of Kiln Program effecting in 23% saving per cycle
 Resourcefully developed:
o Mechanisms to reduce the change over time of Kilns by introducing new handling fixture
o New production practices to reduce time in process
 Significantly implemented newly designed practices in Nasik as well as other multi location plants
 Adroitly suggested:
o Tilting arrangement for reducing change over time in Pressure vessels
o Waste Heat Recovery System in PLC operated Kilns effects in 17 kl saving of fuel consumption per month
 Holds the distinction of settling the production norms, company job confirmation awarded within 9 months, which
otherwise took 1.5 year
 Proficiently implemented material handling system to reduce time to load charges of continuous process
EQUIPMENT HANDLED
 EOT Cranes (5mt, 12 Mt, 20mt, 25 Mt), Pumps, Actuators and Vacuum Pumps
 Pressure Vessels and Hot Gas Generators
 Boilers and Thermic Fluid Heaters

4.  PLC Operated Burner Manifolds and Computer Program of Same
 Pneumatic Conveying Systems
 Electro Static Tar Precipitator (ESP Manufactured By ETS-ELEX)
 Keen Knowledge of Refractory & Furnace Construction and Heat Treatment System of Electrodes
EDUCATION
 MMS in Logistics from IMRT, Nashik with 69.36% in 2005
Stood 1st in College
 PGDBM in Materials Management from IMRT, Nashik with 72.3% in 2004
Stood 1st in College
 BE in Production from KK Wagh College of Engineering with 66.00% in 1996
Stood 7th in University of Pune
Other Course:
 Course of Integrated Materials Handling system by IIT Powai in 2004
CERTIFICATIONS/ TRAININGS
 Lead Auditor in ISO9001-2000 in 2002
 Managing Tough Time in 2003
 SMED, POKA-YOKE, JIT conducted by PDPC in 2003
 Lead Auditor in ISO 14001 in 2005
 SAP system in MM, PP module. Working in same atmosphere in 2006
 Soft Skill Trainings on How to Think Win-Win by Shiv Khera in 2011
 Lean VSM, DOE, SMED by Eminement Management Gurus in 2011
 7 Days Training on Toyota Production system in 2012
 7 Day Program of “Blueprint of Success” by Shiv Khera in 2012
 TOC (Theory of Constraints) and successfully implemented Lead Auditor course of EMS & OSHAS.
 Internal Auditors for 9001-2000 & Experts in VSM/LEAN
 Visited Spain for the New Technology of Process Development Training
IT SKILLS
 SAP in MM & PP Module
SEMINARS ATTENDED
 Best practices of other industries and implemented the same in factory in 2013

PERSONAL DETAILS
Date of Birth: 01st July 1975
Languages Known: English, Hindi, Marathi and Spanish
Current Salary: 22.0 lacs..
Pass port Details: G7545558 Expires on 06/02/2018