Kapil Dev
Production and process excellence leader, has 20 years of experience in operations in automobile and poly-film industry as a production head. He has a sound experience in Polyester (BOPET) lines operations including on coatings, packing cost optimization & expertise in offline coating, printing. He also has experience in best practices at shop floor to minimize the cost of operation.
AREAS OF EXPERTISE
Polyester film lines commissioning and stability; Process improvement through optimization; Cost saving; Occupational Safety & EHS; Products development in Polyester films manufacturing and converting units; Best Manufacturing practices like- lean manufacturing, TPM, Kaizen etc.; Chemical coating development and stabilization.
SELECTED ACCOMPLISHMENTS
Commissioning and Product Development:
- Erection and commissioning of PET lines with latest technology.
- Commissioning of 8.7-meter BOPET Dornier make line having facility in-line coating, direct melt facility from CP along with two extruders additionally.
- Line stabilization with continuous polymerization direct line latest concept.
- Co-extrusion system stabilization (vacuum and dryer both)
- Establishment of transfer coating in product-oriented line at high speed and different type of coating like UV coating, antistatic coating, high barrier coating etc.
- Product development like: Embossable, Heat sealable, High friction, twist wrap, high clear, ultra-clear, matte film, yellow film, opaque white etc.
- Multilayer PET film products range with multiple resin combination products.
- PET resin base silica master batch development through compounding process along with execution and establishment in PET lines.
Business Improvements and Profitability Improvement in PET Production line:
- Production efficiency improvement by applying process optimization.
- Line speed /Width increasing on sustainable basis.
- Waste reduction and utilization in PET lines at different stages.
- Cost optimization in online chemical coating process and low cost chemicals run optimization for over product cost reduction.
- Power / Energy saving projects in Film lines by optimization of blowers / pumps at different stages of process.
- Packing cost optimization and reduction for all type of films.
Technical Support
- Product execution, development of new products with R&D and business development teams.
- Diagnosis and Trouble shooting in PET lines to sustain production rates/ quality of the products.
- Technical support and problem solving at customer end
- Preparation & establishment of SOP’s and WI’s culture in entire film plant for activities and products.
- Process base organization (PBO) and SOP driven system frame work creation and its establishment on company level.
