Prayul Porwal
West Windsor Township,NJ
Summary
Experienced with managing plant operations and ensuring optimal production efficiency. Utilizes strategic planning and resource allocation to streamline processes and improve productivity. Track record of fostering collaborative work environment and driving continuous improvement initiatives. Manufacturing professional with extensive experience in plant operations and production management. Proven history of implementing process improvements that enhance operational efficiency and product quality. Reliable team collaborator with focus on achieving results and adapting to changing needs, bringing valuable organizational and leadership skills to role.
Overview
16
16
years of professional experience
1
1
Certification
Work History
Plant Manager
Aviva Natural Supplements
01.2021 - Current
- Oversaw all facets of plant operations, ensuring smooth functioning of manufacturing processes, adherence to production schedules, and attainment of quality standards
- Directed a team of supervisors, technicians, and production workers to achieve operational excellence
- Spearheaded initiatives to optimize production efficiency, reduce costs, and enhance product quality
- Implemented lean manufacturing principles and methodologies to streamline workflows, resulting in a 28% increase in production efficiency within the first year
- Implemented and maintained rigorous quality control measures to uphold product integrity and compliance with regulatory standards
- Developed and enforced standard operating procedures (SOPs) to ensure consistent quality throughout the production process
- Collaborated with cross-functional teams including engineering, quality control, procurement, and logistics to resolve operational challenges and improve overall performance
- Facilitated communication and alignment between departments to streamline processes and improve productivity
- Prioritized safety protocols and ensured compliance with Occupational Safety and Health Administration (OSHA) regulations
- Implemented safety training programs and conducted regular inspections to maintain a safe working environment, resulting in zero lost-time incidents over a period of three years
- Fostered a culture of continuous learning and development within the plant workforce
- Provided coaching, training, and performance feedback to employees, facilitating their professional growth and career advancement
- Overseeing maintenance operations, implementing preventive maintenance programs, and optimizing equipment reliability
- Managing maintenance teams, coordinating schedules, and ensuring compliance with regulatory standards
- Proficient in diagnosing and troubleshooting equipment issues, reducing downtime, and maximizing production efficiency
- Strong leadership qualities combined with effective communication and problem-solving abilities
- Committed to driving continuous improvement initiatives and fostering a culture of safety and reliability within the maintenance department
- Implemented a new production system that increased equipment utilization by 25%
- Led a team that achieved a 30% reduction in production waste through process optimization
- Effectively spearheaded the attainment of the company's inaugural UL GMP Certificate
- Increased production efficiency by optimizing plant layout and implementing process improvements.
- Reduced costs by eliminating materials waste and unnecessary labor hours.
- Directed employees and related programs to maximize team productivity and facility output.
- Provided direction and leadership to all levels of employees and managers.
- Boosted employee morale and productivity through effective leadership and motivational techniques.
- Led, trained and coached plant staff to facilitate high levels of productivity and quality.
- Monitored and evaluated plant performance to identify areas for improvement and take corrective measures.
- Balanced labor needs with production schedules to optimize workforce utilization while maintaining output targets.
- Maximized plant safety through proactive strategies and well-structured training.
- Oversaw daily operations of 80000 sq. ft. manufacturing plant.
- Forecasted future production needs accurately, allowing for strategic decision-making regarding staffing levels, equipment investments, and inventory management.
- Maintained quality of product with robust inspections and assessment team.
- Managed direction and planning for plant with focus on optimization of daily functions, exceeding customer expectations, and achieving KPIs.
- Mentored and developed staff members, promoting professional growth opportunities within the organization.
- Collaborated with sales team to align plant capabilities with customer demands, fostering long-term business relationships.
- Identified and resolved process and equipment issues to minimize production downtime.
- Conducted thorough root cause analyses on production issues, identifying solutions for continuous improvement efforts.
- Promoted collaborative work environment to motivate and engage staff to achieve company objectives.
Manufacturing Manager
Ingenuity Beverages, LLC
10.2019 - 11.2020
- Maintain and supervise workflow by facilitating steps of the work order process and priorities throughout the bottling and packaging teams
- Ensure accurate record-keeping systems and enforcing organization standards
- Creating action plans for process improvement and implementing those action plans to support company metrics, training opportunities or process corrective actions
- Overseeing routine cycle counts performed on raw materials, packaging materials, machine parts
- Provide direct supervision to QA inspector, Laboratory Supervisor and Sanitation Supervisor, including providing training and development opportunities, and conducting performance reviews, coaching sessions as required by NSF and SGS certification
- Maintain and improve product quality by completing product and compliance audits, investigating consumer complaints; collaborating with other members of management to resolve issues
- Maintain the food safety aspect of the plant by periodically performing internal audits of the facility to verify that procedures mandated by the company, state and Federal governmental agencies are being adhered to
- This includes GMPs, Sanitation, Food Safety Plans, and Safety
- Maintain all aspects of the Quality Assurance Laboratory, including microbiological, chemical, physical and sensory aspects of all food products manufactured at the facility
- This also includes coordination of the sampling and testing with production
- Supervise and provide training to production personnel for continuous process improvement, prioritize areas of opportunities for improving methodology and processes
- Comply with all GMPs, food safety and quality procedures to ensure that food safety and quality objectives are met
- Investigate CAPAs and report to management for approval
- Investigate Root cause analysis for production downtime, identify overall equipment efficiency, prepare daily production reports for estimating completion of work orders
- Devised and administered cost control initiatives saving .
Production Manager
Health Concepts LLC
01.2016 - 10.2019
- Providing leadership and daily direction, communicating job expectations, establishing priorities, scheduling and assigning personnel, monitoring progress and reviewing job results of Nutraceutical Manufacturing Operations team
- Maintaining workflow by facilitating steps of the work order process and priorities throughout the Bottling and Packaging Teams; ensuring accurate record-keeping systems and enforcing organization standards as per GMP and cGMP
- Creating and maintaining production plan for Machine Technicians and Operators; resolving problems, answering questions and responding to requests
- Compiling and analyzing production and downtime records and data, performance observations and initiating all follow up with quality management
- Creating action plans for process improvement and implementing those action plans to support company metrics, training opportunities or process corrective actions
- Overseeing routine cycle counts performed on raw materials, packaging materials, machine parts
- Maintaining company equipment, raw materials and consumables by calling for repairs, ordering supplies and overseeing the performance of routine maintenance on machines
- Maintaining safe and clean work environment by educating and directing personnel on the use of equipment and resources; maintaining compliance with established policies and procedures
- Fostering a spirit of cooperation within and between departments; Contributing to team effort by accomplishing related results as needed
- Directing department operations to produce products in quantities specified by production schedules, in accordance with design and quality specifications, within cost objective, and with emphasis on meeting ship schedules
- Devised and administered cost control initiatives saving.
Purchase Co-Ordinator and Fulfillment Assistant
Health Concepts LLC
12.2014 - 12.2015
- Oversee and perform all purchasing activities for raw materials, production supplies, non-production supplies and freight
- Monitor and place POs for primary and secondary materials at the right price, time, and place
- In addition, coordinate the forecast, scheduling, and releases of trucks for prime materials
- Establish, coordinate, and enforce spending budgets
- Source and manage inventories of maintenance, repair, and operational supplies; place and approve orders when necessary; manage building facilities services – regarding pricing negotiation and supplier performance; manager of vendor management programs
- Negotiate pricing with vendors
- Monitor inventory levels to ensure constant supply
- Develop and execute purchasing strategies concurrent with overall company strategy
- Receive materials coming into the warehouse by vendors
- Check merchandise to ensure that it conforms to order sheets
- Verify the quantity and quality of each item by checking them individually
- Prepare shipments to be sent at Amazon Fulfillment Center (AFC) and report damaged items to vendor customer service for credit and refunds
- Maintain expected levels of stock at AFC
- Control inventory by implementing cost reduction strategies
- Develop, lead and execute purchasing strategies software Teikametrics, Appeagle and Amazon seller central accounts
- Track and report key functional metrics to reduce expenses and improve effectiveness
- Craft negotiation strategies and close deals with optimal terms
- Gather and analyze data, study sales and inventory records, identify suppliers, and stay on top of factors affecting supply and demand to forecast current and future costs of needed products and materials
- Manage private website for sales, purchase and order related queries
Product Development Engineer
BioNeutral Group Inc.
12.2014 - 06.2015
- Develop formulations for Odor elimination, Multipurpose Cleaner applications including conducting experiments to develop new products to improve the existing ones
- Worked on Y-giene a hospital-level Sporicide and Sterilant; a true hospital and healthcare facility grade cleaner and disinfectant
- Analysis of various formulations in eliminating odor of different concentration
- Formulating of samples and large batch of Y-Giene which is a combination Sterilant and Sporicide, also eradicating broad spectrum of pathogens
- Formulation of O-Giene in small and large batches
- O-Giene is a fast, complete elimination of noxious odor, helps in eradication of stains from hard and soft surfaces
- Develop formulations for odor elimination and eradication of stains application including conducting experiments to develop new products or improve existing products
- Persuaded quality control tests like viscosity, pH levels and scrub tests
- Measurement of Odor Elimination absorption using formaldehyde sample tube (GASTEC Detector Tube No
- 91L – formaldehyde, QC No
- 40903) and acetic acid sample tube (GASTEC Detector Tube No
- 81L – acetic acid, QC No
- 40794)
- Maintain laboratory documentation ensuring compliance to test methods and specifications
- Maintain personal training logs to comply with current SOP requirements
Purchasing Manager
N Porwal & Co.
10.2010 - 12.2014
- Maintain records of goods ordered and received
- Locate vendors of materials, equipment or supplies, and interview them in order to determine product availability and terms of sales
- Prepare and process requisitions and purchase orders for supplies and equipment
- Review purchase order claims and contracts for conformance to company policy
- Develop and maintain a complete understanding of the business environment, market trends and issues that will impact the business
- Implemented numerous business optimization projects and reporting tools that improved efficiency, reduced expenses, labor costs and maximized profits by automating outdated manual processes
- Manage team at office for situating of materials and packaging for delivery
Product Development Engineer
Applechem Inc
10.2008 - 10.2010
- Develop formulations for Dispersion and Gel application including conducting experiments to develop new products or improve existing products
- Worked on the rubber based polymer Styrene Butadiene to produce Hard Gel and Semi-solid Gel, which helped to make diaper rash cream, lipsticks, lip balms, daily moisture, body cream
- Executed experiments to find the best composition of the cosmetic items like skin care products, foundation, diaper rash, shampoo and sun block formulations using own home products as per cGMP, cGLP guidelines
- Sample preparation of ZnO and TiO2 dispersions and analyzed them in UV-Vis Spectroscopy
- Formulated, customized base products of cosmetics at lab scale batched and large scale manufacturing as per OSHA guidelines
- Persuaded quality control tests like viscosity, pH, Spreadability, Stability, invitro studies
- Successfully worked on multiple projects simultaneously until product launch
Research Assistant
New Jersey Institute of Technology
07.2009 - 05.2010
- Blind Source Separation (BSS) technique explicitly Generalized Morphological Component Analysis (GMCA) is being designed for detection of sources embedded in vergence movements of eye
- My role is to modify the algorithm for the given application that would endow with most excellent results
- Mostly aimed at signal processing the data collected from an experiment where a subject is given near and far 2 degrees step stimulus
Education
Master's Degree - Biomedical/Medical Engineering
New Jersey Institute of Technology
Newark, NJ01.2015
Masters - Electrical Engineering
New Jersey Institute of Technology
Newark, NJ01.2010
Bachelor of Engineering - Electronics and Telecommunication
Vishwakarma Institute of Information Technology
INDIA01.2007
Skills
- Plant Operations
- Quality Auditing
- FDA GMP
- Good Manufacturing Practice (GMP)
- Formulation
- NSF
- OSHA
- FDA compliance
- HIPAA Compliance
- Quality Assurance
- Quality Control
- Quality System
- Production Planning
- Inventory Management
- Safety management
- Continuous improvement
- Performance improvements
- Production scheduling
- Scheduling
- Facility management
- Team building and development
- Logistics coordination
- Work delegation
- Lean manufacturing processes
- Cost control
- Schedule management
- Six sigma expertise
- Resource coordination
- ISO compliance
- Waste reduction
- Facilities maintenance
- Project coordination
- Cost reporting
- Six sigma
- Process re-engineering
- Production equipment maintenance
- Cost reduction strategies
- Equipment upgrading
- Operational auditing
- Decision-making
- Safety assessment
- Team development
- Troubleshooting skills
- Plant maintenance
- Staff training
- Operational efficiency
- Team management
- Quality control management
- Workflow management
- Inventory oversight
- Strategic thinker
- Operating budgets
- Team Training
- Production problem resolution
- Quality assurance
- OSHA regulations
- Equipment troubleshooting
- Inventory control programs
- Staff scheduling
- Resource management
- Lean manufacturing
- Critical thinking
- Cross-functional collaboration
- Product planning
- SAP
- Plant and warehouse operations
- Project management
- Operations management
- Production planning
Equipment Experience
- Patterson Kelly – 75 cu ft V-Blender
- ACG AF90T, AF40T, Bosch and NJP 2000 and 3500 Encapsulation Machine
- Cadmach D-Tooling and B-Tooling Compression Machine
- Fitzmill Milling Machine
- Kaps All V-8 Liquid Filling Machine
- Modular Packaging Counter Machine
- CVC Cottoner, Desiccant, Labeler Machine
- Kaps All Capper Machine
- Ink Jet Printers and many more
Accomplishments
Production Efficiency: Implemented lean manufacturing principles, resulting in a 28% increase in production efficiency within the first year at Aviva Natural Supplements.
• Equipment Utilization: Implemented a new production system that increased equipment utilization by 25% at Aviva Natural Supplements.
• Waste Reduction: Led a team that achieved a 30% reduction in production waste through process optimization at Aviva Natural Supplements.
• GMP Certification: Successfully spearheaded the attainment of Aviva Natural Supplements’ inaugural UL GMP Certificate.
• Safety Record: Maintained a safe working environment at Aviva Natural Supplements, resulting in zero lost-time incidents over a period of three years.
• Process Improvement: Created action plans for process improvement and implemented those action plans to support company metrics, training opportunities, or process corrective actions at Ingenuity Beverages, LLC and Health Concepts LLC
• Business Optimization: Implemented numerous business optimization projects and reporting tools that improved efficiency, reduced expenses, labor costs, and maximized profits by automating outdated manual processes at N Porwal & Co.
Certification
Six sigma
Lab view
Altium designer 2014
Neuro solutions
ERP
Protel 99 SE
Proteus labcenter 8
Microwind
Multisim 12
H-spice
Mentor graphics 2007
Timeline
Plant Manager
Aviva Natural Supplements
01.2021 - Current
Manufacturing Manager
Ingenuity Beverages, LLC
10.2019 - 11.2020
Production Manager
Health Concepts LLC
01.2016 - 10.2019
Purchase Co-Ordinator and Fulfillment Assistant
Health Concepts LLC
12.2014 - 12.2015
Product Development Engineer
BioNeutral Group Inc.
12.2014 - 06.2015
Purchasing Manager
N Porwal & Co.
10.2010 - 12.2014
Research Assistant
New Jersey Institute of Technology
07.2009 - 05.2010
Product Development Engineer
Applechem Inc
10.2008 - 10.2010
Master's Degree - Biomedical/Medical Engineering
New Jersey Institute of Technology
Masters - Electrical Engineering
New Jersey Institute of Technology
Bachelor of Engineering - Electronics and Telecommunication
Vishwakarma Institute of Information Technology