Rajesh.R.Wadhwa ★Manufacturing Leader

Director Of Operations at MedGyn Products, Inc.
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Location
Woodridge, Illinois, United States, US

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Experience

    • United States
    • Medical Equipment Manufacturing
    • 1 - 100 Employee
    • Director Of Operations
      • 2021 - Present

      Westmont, Illinois, United States

    • United States
    • Appliances, Electrical, and Electronics Manufacturing
    • 1 - 100 Employee
    • Plant Manager
      • Sep 2019 - Dec 2021

      Gaylord, Michigan, United States

    • United Kingdom
    • Manufacturing
    • 700 & Above Employee
    • General Manager of Operations ★ Successful Turnaround in less than 12 Months
      • 2017 - Aug 2019

      Chicago, IL I was recruited to Essentra in 2017 as a Management Consultant, where I was brought in to introduce process and operations improvements. Due to my initial success, within 9 moths I was transitioned into a Vice President of Operations and General Operations Manager role. As GM of Operations, I held complete ownership for P&L management, CAPEX management, safety, engagement, on-time delivery, backlog, and budgeting, as well as operations performance for 3 sites across the United States and… Show more I was recruited to Essentra in 2017 as a Management Consultant, where I was brought in to introduce process and operations improvements. Due to my initial success, within 9 moths I was transitioned into a Vice President of Operations and General Operations Manager role. As GM of Operations, I held complete ownership for P&L management, CAPEX management, safety, engagement, on-time delivery, backlog, and budgeting, as well as operations performance for 3 sites across the United States and Mexico. SELECTED HIGHLIGHTS & ACHIEVEMENTS ✔ Within the first 12 months, I achieved significant gains to Safety (50%), Engagement (10%), and to ON-Time Delivery (10%). ✔ Reduced backlog from $600K to $100K in just 6 months. ✔ In the first 6 weeks, played a key role in improving on-time delivery from 50% to 92% ;Led quality engineering teams to analyze customer complaints and implement corrective actions. ✔ Decreased labor costs 5% while simultaneously increasing production volume capacity by maintaining a hands-on approach to projects and programs. ✔ Led plant operations with 4 shifts in a 24/7 environment, and led 200+ employees with 80 injection molding and 20 automated machines. ✔ Achieved a 1-year savings at a single plant of $1.3M after devising and introducing strategic initiatives with a $3M annual CAPEX budget. Show less

    • United States
    • Manufacturing
    • 1 - 100 Employee
    • Director of Operations ★ Leadership of 225 Plant Employees running 24/7 Operations
      • 2015 - 2017

      Chicago, Illinois I joined Home Products International in 2015 as Director of Operations, and over the next two years led 225 total reports in a 4-shift union plant with 24/7 operations. SELECTED HIGHLIGHTS & ACHIEVEMENTS ✔ Improved profit 3% and plant efficiency 8% within the first year of joining the company. ✔ Achieved a record 180+ days without an OSHA recordable, compared to 14 recordables in the prior 12 months of joining the company. ✔ Delivered an 8% YOY increase in… Show more I joined Home Products International in 2015 as Director of Operations, and over the next two years led 225 total reports in a 4-shift union plant with 24/7 operations. SELECTED HIGHLIGHTS & ACHIEVEMENTS ✔ Improved profit 3% and plant efficiency 8% within the first year of joining the company. ✔ Achieved a record 180+ days without an OSHA recordable, compared to 14 recordables in the prior 12 months of joining the company. ✔ Delivered an 8% YOY increase in revenue to $90M; focused on collaboration and involvement at peak, resulting in the highest bonus payouts in more than a decade. ✔ Navigated a $3M investment to guide complex state-of-the-art projects for In Mould Labeling and compression injection molding; sourced 40+ molds from China in 2 years. Show less

    • South Africa
    • Plant Manager ★ 5% Plant Profitability Improvement in 3 Months
      • 2014 - 2015

      Greater Chicago Area I joined Ennis Flint in 2014 as Plant Manager at a time when the plant was undergoing significant turmoil. Within 3 months I was able to improve plant profitability more than 5%, in addition to reducing lead time by 2 weeks and producing a 10% CAPEX savings. However, within just 10 months of joining the company, the plant was relocated to North Carolina.

    • 1 - 100 Employee
    • Plant Manager ★ 4-Year Revenue Growth from $30M to $70M
      • 2010 - 2014

      Fort Wayne, Indiana Area I was recruited to Group Dekko in 2010 as Plant Manager, and over the next four years I was responsible for complete performance and operations results for the 3-shift non-union plant running 24/5. I led team of 6 direct reports and 200+ indirect reports, and provided leadership that created a laser-like focus on quality, stability, on-time delivery, and customer satisfaction. SELECTED HIGHLIGHTS & ACHIEVEMENTS ✔ In just 6 months of joining the company, I took the plant… Show more I was recruited to Group Dekko in 2010 as Plant Manager, and over the next four years I was responsible for complete performance and operations results for the 3-shift non-union plant running 24/5. I led team of 6 direct reports and 200+ indirect reports, and provided leadership that created a laser-like focus on quality, stability, on-time delivery, and customer satisfaction. SELECTED HIGHLIGHTS & ACHIEVEMENTS ✔ In just 6 months of joining the company, I took the plant from loss to profitability. ✔ Played a key role in driving 4-year revenue growth of $30M to $70M. ✔ Introduced more than $1M in Lean Continuous Improvement programs that delivered $700K in annualized savings within the first 3 months. ✔ Fostered strong relationships with key customers, including Whirlpool, Phillips/Zimmer, Herman Miller, and Harley Davidson. ✔ Saved the Whirlpool relationship by reducing quality PPM from 12,000+ to less than 1,000 in 6 months. Within 18 months, the company was selected as a Top 5 Preferred Supplier. ✔ Won the Operational Excellence Award for Manufacturing Variance Reduction. ✔ Reduced scrap by $450K, representing more than 1.5% of net sales. Guided the plant through the successful renewal certification of ISO 9001 and ISO 13485. Show less

    • Plant Manager & Engineering Manager ★ Successful Turnaround in 6 Months
      • 2008 - 2010

      Kalamazoo, Michigan Area I was recruited to AEES, formerly Aloca Electrical & Electronic Solutions, in 2008 as an Engineering Manager, and was quickly promoted to Plant Manager. In this role, I led a 9 member team comprised of Manufacturing engineers, Program Managers, Quality Engineers, and Costing Engineers. Processes included 111 Process Injection Molding machines, 70 Automated Assembly machines, as well as Sonic Welding and Vibration Welding, 128 cavity molds with Hot Runner system and poke-hokes with vision… Show more I was recruited to AEES, formerly Aloca Electrical & Electronic Solutions, in 2008 as an Engineering Manager, and was quickly promoted to Plant Manager. In this role, I led a 9 member team comprised of Manufacturing engineers, Program Managers, Quality Engineers, and Costing Engineers. Processes included 111 Process Injection Molding machines, 70 Automated Assembly machines, as well as Sonic Welding and Vibration Welding, 128 cavity molds with Hot Runner system and poke-hokes with vision systems, Metal Stamping, and Terminal Stamping processes. SELECTED HIGHLIGHTS & ACHIEVEMENTS ✔ Improved profitability 6% YOY by introducing systematic and scientific molding techniques to eliminate quality concerns. ✔ Saved $500K in 6 months by training and deploying operational excellence teams across the plant. ✔ Stabilized processes to improve quality on 100 sorters at CS2 level sort. ✔ Guided the company’s plant’s move from Michigan to Mexico, including leading recruiting, interviewing, and training of a new plant leadership team in Mexico. ✔ Launched plant-wide operational excellence initiatives that delivered a $1M annual recurring cost savings, far exceeding management benchmarks. Show less

    • Manager, Plastics Engineering
      • 2007 - 2008

      Greater Milwaukee Area Oversaw manufacturing design for plastics and outsourcing materials for production, including casting, plastics, and sheet metal. Directed, planned, and reviews static and dynamic FEA analysis, with global-level project implementation

Education

  • University of Massachusetts Amherst
    MSME, Mechanical Engineering with Plastics
  • Bharatiya Vidya Bhavans Sardar Patel College Of Engineering
    Bachelor of Engineering (B.E.), Mechanical Engineering
  • Jai Hind College
    Science

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