RAJEEV.V JOSHI

Mumbai India

Professional Summary

• IGBC-DCS Accredited professional
• Over 3 decades of rich experience in Plant Operations, Maintenance, Project Management, Supplier Management, Process Management and Quality Assurance in the Chemical industry.
•  Presently associated with Borax Morarji Limited, Ambernath, District Thane (Maharashtra) as Works Manager.
• Adroit in managing overall operations and commercial activities in the plant with a view to enhancing the operational nefficiency, eliminating obsolescence and achieving cost reduction.
• Expertise in developing new products, identifying new routes and successfully commissioning the product post trial.
• Resourceful in vendor development, curbing rework & rejection, materials management and inventory control.
• Deft in reviewing processes, effectuating cost control measures, and building a culture of continuous improvement to help the organisation sustain operations amidst tough market conditions.
• Hands on experience in implementation of safety management systems as well as QMS (ISO 9001:2000). Led the organisation for certificate up-gradation to ISO 9001:2008.
•  Served as Management Representative of the organisation for ISO implementation and audits since 2004.
•  An enterprising leader with excellent communication, analytical, problem solving & man management skills.

Organisational Experience

Since Feb’82 with Borax Morarji Limited, Ambernath, District Thane (Maharashtra)

The Growth Path                

Areas of Strength

Present Role

Ø  Supervising overall plant activities encompassing close cross-functional coordination and compliance with QCD parameters in line with the organisational plan. Ensuring achievement of pre-defined targets as per the production plan.

Ø  Overseeing the implementation of activities regarding new equipment introduction, capacity enhancement and conducting new product trials.

Ø  Streamlining processes to facilitate smooth production, cost reduction & enhance productivity.

Ø  Planning and conducting lab trials of new products & submitting feasibility report along with percentage yield and payback period (Products include Zinc Borate, DOT, and Sodium perborate).

Ø  Managing smooth commissioning of the product post successful completion of the trials.

Ø  Interfacing and sustaining healthy relations with government agencies (like MPCB, FDA,, FCO and  Factory Inspectorate) for securing statutory clearances, permissions and fulfilling all formalities as outlined in statutory guidelines.

Ø  Serving as Member of the core group for initiating & implementing strategies to attain operational excellence.

Ø  Deploying and managing resources to enhance productivity in all four M’s of management.

Ø  Ensuring effective implementation of various safety guidelines. Conducting periodic inspection of the procedure for ascertaining compliance.

Ø  Working towards augmenting customer satisfaction levels by conducting Customer Feedback Survey. Reviewing the inputs and taking appropriate action in the direction.

Ø  Maintaining amicable relations with workers and complying with all provisions of relevant Acts, as applicable to the industry.

Ø  Imparting on job and in house training to the workers to improve their skills and escalate productivity.

Key Highlights

•  Essayed a major role in the successful commissioning of:
  •  Zinc Borate with Zinc Sulphate & Borax as the raw materials (key ingredients of the product).
  •  Various products like Agribor, Sodium Perborate, Sodium Silico Flouride, Dot, Ammonium Penta Borate, Injecta, Parabase Aniline Ester ,Benzene Sulfonic Acid.(B.S.A) & Sod Salt of B.S.A.
  •  DM Plant including developed versions of Cation & Anion of resin for producing special quality grade (SQ) of Boric Acid.
•  Initiated process improvement by identifying and introducing new route of Zinc Borate.
•  Commenced the successful production of Borax & Boric Acid from Ulexite (new raw material), and acquired the pioneer status for the production of Borax.
•  Coordinated energy audits for Borax & Boric Acid plant. Major findings/ actions included:
  •  Installed Motors in one section of the plant were over rated.
  •  Curtailed the consumption by optimising Motor Rating (HP) & achieved savings worth Rs. 50,000 on a monthly basis.
  •  Replaced tube lights in Lighting Section with CFL Lamps, which saved Rs. 10,000 per month.
•  Instrumental in the implementation of 5S , ISO 9001:2000 QMS, EMS and OHSAS as Management Representative. Led our organisation to achieve ISO 9001;2008 for our QMS on 10.08.2010 & is being implemented effectively.
•  Recorded reduction in product losses from 4.5% to 2.25% by revamping washing process, which generated savings to the tune of Rs. 2.2 Lakhs p.a.
•  Pivotal in replacing process S.S. pipelines with thermoplast (as liquor is more prone to stress corrosion) with SS 316 pipelines. Switched over to MS/ PTFE, MS/ PP, & MS Hyplon materials depending on the severity of liquor. As a result of this, reduced recurring maintenance expenses & frequent breakdowns; as well as enhanced productivity and achieved higher life of Pipelines, say up to 4 times of earlier cost of SS pipelines.
•  Spearheaded the introduction of the use of Demineralised Water Plant in the process which reduced downtime, enhanced productivity and ensured the achievement of conforming product on continuous basis.
•  Pivotal in the introduction of vacuum flash crystallisation in place of conventional crystallisation. On account of the introduction of vacuum flash crystallisation, overall expenses in terms of electricity and equipment maintenance have   come down drastically and saved the company Rs. 28 Lakhs annually.
• W.r.t compliance of MPCB conditions, sought Membership of

(1) MUMBAI WASTE MANAGEMENT LTD. for utilising Common Hazardous Waste Treatment Storage Disposable facility at TALOJA.

(2)Chikhloli Morivali Effluent Treatment a,local body for utilising   their facility.

Previous Experience

Dec’80 to Feb’82 with Modern Dye Chem Pvt. Ltd., Nandesari GIDC, Vadodara as Shift Engineer

Key Highlights

·          Efficiently handled P-Anisidine, O-Anisidine, P&O Toulidine Plants and Dyes Intermediates, which involved all flameproof connections & very high degree of safety compliance.

·          Played a key role in the development of a system with Sodium Chloride Dozing to recover parent product from mixture of Organic & Aqueous layer, resulting in enhanced productivity.

Nov’79 to Nov’80 with Amar Dyechem Ltd., Shahad (near Kalyan), Mumbai as Chemical Engineer

·          Working in the Dye Intermediate Plant for the production of Beta Napthol.

Academia

·          PG Diploma in Management Studies from University of Mumbai, Mumbai in 1989.

·          B.Tech. (Chemical) from Laxminarayan Institute of Technology, Nagpur in 1979.

Professional Development

·   Successfully completed Lead Auditor Training Course (Based on OHSAS 18001:2007) in June 2013.

·          Attended 1 day transition course  for ISO 9001:2008 in Oct. 2009

·          Attended 2-day Transition Course for ISO 9001:2000 in 2003.

·          Passed Lead Auditor’s Course for ISO TQMI, Mumbai in December 1999.

·          Certified FDA Approval for Manufacturing from Food & Drug Administration, Maharashtra in Sept. 1993.

Professional Memberships

·          Member of Indian Institute of Chemical Engineers, Kolkata since June 2003.