PRADEEP KUMAR AVUDURTHI

Roles and Responsibilities:

• Responsible for overall day to day operations inside factory, right from receiving of raw ingredients including raw milk and packaging materials to till finished products and maintain quality standards among all production stages.
• Handling 2 million liters/week of Fresh which includes Milk and its variants, Yoghurt and its variants, fermented products and its variants. Handling Fresh filling of FOGG / DAWSON / Index6 / Trepko / Primodan filling machines for packing variant of fresh, fermented SKUs. SPX/APV/Tetrapack Process which is fully automated plant from raw milk receiving to storage.
• Casualties and incidents are reduced to 2% over period of 3 years with regular toolbox talks, efficient hazard reporting and implementing 5S principles.
• Reduced markets complaints from 2 CPMU to 0.5 CPMU by taking preventive measures to eliminate quality defecting factors.
• Impromptu safety audits performed to promote safe work environment. Awareness trainings are conducted to 100 % of employees about “3S” principles and “Clean as you go “to aware
  about all work-related hazards.
• Set yoghurt complaints are reduced over 80% by implementing new Improved drain system.
• Microbial contamination cases brought below 0.1% by introducing new yoghurt nozzles CIP system.
• Internal rejections are reduced from 4 % to 0.1 % in one year by streamlining process of yoghurt manufacturing.
• Repeated market complaints are avoided by effective root cause analysis and proper implementation of corrective actions.
• Increased internal GMP audit scoring from 51% to 66% by prompt and long-term actions.
• Internal complaints of set yoghurts and Laban based products are reduced to 1% with effective monitoring of mixing procedures and
  processes.
• Annual trainings related to GMP's, GHP's and food safety are provided to all employees to achieve FSMS regulations.
• Productivity has increased from 160 to 178 lits/man hour with effective manpower planning and training to employees.
• Machine utilization percent has increased from 70% to 92 % in peak seasons by adjusting CIP timings and workers duty schedules.
• Efficiency of machines increased from 67% to 80% with proper preventive maintenance planning.
• OEE has increased to 68 % by reducing quality defects in filling process.
• About 1.5 million AED saved by reducing LIP from 2.58% to 1.52 % by introducing new reprocessing methods.
• Packaging material losses are kept as high as 0.8% by changing production sequence.
• Achieved 0% variance in production vs demand by coordinating with sales and prioritizing production schedule accordingly.
• Internal audit NCR's are reduced 50% with proactive approach and maintaining production and filling records accurate.
• Achieving the quality & Production targets, All KPI's are achieved 100% by communication and on-going reinforcement of production performance indicators/requirements.
• Chemical consumption reduced to 50% than budget, by training operators about continuous dosing procedure and regular monitoring.
• 20 % of homogenization power consumption reduced by avoiding homogenization of skimmed milk and dual homogenization of low fat yoghurt.
• Machine down time reduced to maximum of 3 hrs day by identifying and providing all snag lists to engineering team before performing preventive maintenance.
• Supporting production manager in preparation of annual budget and CAPEX requirements.
• Set up and calibrated machinery to meet specific production requirements and meet desired tolerances.
• Partnered with managers to identify and capitalize on sales trends and brand initiatives.
• Participated in cross-functional team-building activities.
• Facilitated training for associates through daily coaching and regular performance appraisals.

Professional Highlights:

• 30 % of water utilization for cleaning has reduced by using water guns to control free flow of water.
• Reduced yoghurt market complaints by 80% with implementing new draining system and introduced new type of nozzle cleaning methods to control microbial contamination.
• Reduced CIP chemical consumption by revising existing process. Saved 80,000 AED per year by reducing chemical consumption.
• Installed new PPE stations throughout plant to avoid excess use of gloves and beard snots.
• Improved personal hygiene standards of employees by frequent personal hygiene audits and trainings.
• Risk assessment, HACCP plan and SOP's are developed for newly installed pouch, processing unit and glass bottles filling machines.
• Leaded team while commissioning Yoghurt bulk fillers-TREPKO, Fruit Yogurt Filler-TREPKO,GT pack-EVERGREEN, Pouch filler Milk Pack(NOVIY VEK) and glass bottle line-INDEX 6.
• Commissioned SPX Processing Unit From Receiving of raw milk Unit till storage which includes 1 Raw milk Silo of150k ,1 Mixing Unit, 2Mixing Tanks, 2 Cream Storage Tanks,1 Pasteurizer of 20K/hr. PHE.