Kavali Rajesh

Co-Founder

Bengaluru, Karnataka, India9 yrs 3 mos experience
Most Likely To SwitchHighly Stable

Key Highlights

  • Proven track record in managing multi-facility operations.
  • Expertise in Lean Six Sigma methodologies.
  • Achieved significant improvements in service levels.
Stackforce AI infers this person is a Manufacturing Operations Expert with a focus on Supply Chain and Process Optimization.

Contact

Skills

Core Skills

Operational ExcellenceProduction ManagementSupply Chain Planning

Other Skills

Capacity PlanningCommunicationCost ManagementCross-Functional CollaborationFinancial MonitoringLeadershipLean Six SigmaLogistics ManagementManagementManufacturing OperationsNetwork OptimizationProcess EngineeringProcess ImprovementProcess OptimizationProcess Optimization & Troubleshooting

About

Rajesh Kavali, Unit Head at Pidilite Industries Limited | Chemical Engineering Graduate, NIT Surathkal Experienced & continuous learner in manufacturing operations, supply planning, and distribution, with a proven track record of managing complex, multi-facility operations. At Pidilite, I have driven improvements in service levels, enhanced manufacturing efficiency, and optimized production processes through structured planning and cross-functional collaboration. Previously at Dr. Reddy’s Laboratories, I gained deep expertise in shop floor management, process engineering, production optimization, and supply chain planning. Skilled in Lean Six Sigma methodologies, I am passionate about driving operational excellence and building high-performance teams that deliver sustainable results.

Experience

Nitkonnect

Core Team Member

Sep 2025Present · 6 mos · Bengaluru, Karnataka, India

Pidilite industries limited

3 roles

Unit Head

Promoted

Aug 2025Present · 7 mos · On-site

Production ManagementProcess Optimization & TroubleshootingProcess EngineeringCommunicationLeadershipTeamwork+2

Assistant Manager - Supply Planning & Distribution

May 2024Jul 2025 · 1 yr 2 mos · On-site

  • 1. Oversaw Mfg-Operations across 15+ plants, supported by a structured review mechanism for a ₹1000 Cr+ business portfolio.
  • 2. Improved service levels from 65% (2022) to 90% (2025) by enhancing stock availability through robust production planning and
  • 3. Provided rolling and monthly production plans aligned with plant capacities, ensuring timely RM/PM availability through close coordination with the procurement team.
  • 4. Led quarterly capacity planning to identify gaps and implement corrective action plans for seamless operations.
  • 5. Actively highlighted and resolved supply-demand challenges during S&OP meetings with cross-functional teams.
  • 6. Successfully coordinated and implemented upgraded formulations, new product launches, and new packaging artworks.
  • 7. Introduced weekly planning in collaboration with Sales and Demand teams, optimizing production schedules and RM/PM inventory management resulted in Service level.
  • 8. Executed network optimization initiatives, resulting in faster service and annual freight savings of approximately ₹0.6 Cr
  • 9. Derived most cost effective and feasible Supply and Distribution network to cater to market requirements from Mfg Plant to Customer via RDC & Depo's.
  • 10. Maintained and reviewed master data in Vector Flow, including seasonality, phase-in/phase-out, group norms, location mapping, SKU mapping, and excess inventory planning.

Assistant Manager - Manufacturing Operations

Oct 2022Apr 2024 · 1 yr 6 mos · On-site

  • 1. Oversaw manufacturing operations across 17 plants, including 7 owned facilities, 6 job work partners, and 4 P2P model units, ensuring adherence to standard operating procedures.
  • 2. Implemented critical initiatives such as deviation management, productivity enhancement, and 5S implementation across all manufacturing sites.
  • 3. Collaborated closely with cross-functional teams including R&D, Sales & Marketing, Supply Chain, Procurement, Finance, and Quality to ensure seamless operations.
  • 4. Enhanced plant capacities by reducing Batch Cycle Time (BCT), driving efficiency and throughput.
  • 5. Led manufacturing cost budgeting and ongoing cost monitoring to support financial targets.
  • 6. Conducted monthly operational reviews, preparing dashboards and reports covering IRM, project progress, quality initiatives, NMSM product tracking, blocked stock analysis, and disposal documentation.

Dr. reddy's laboratories

2 roles

Production Incharge

Oct 2021Sep 2022 · 11 mos · Vishakhapatnam, Andhra Pradesh, India · On-site

  • 1. Enhanced productivity of APIs like Valsartan, Levetiracetam, Rivaroxaban by using Lean Six Sigma tools like Overall Equipment Effectiveness (OEE), Value Stream Mapping (VSM), Why-Why analysis, Fish bone analysis.
  • 2. Led shift operations for critical product portfolio, ensuring smooth and efficient production execution, maintaining safety and quality standards.
  • 3. Successfully implemented Total Productive Maintenance (TPM) – Jishu Hozen (JH) Steps 1 through 5, driving equipment reliability and process excellence.
  • 4. Honored to receive the GOLD Trophy Award in the MURI Category at the 11th Edition of the CII National 3M Competition, held on 28–29 October 2021.
Production ManagementProcess Optimization & TroubleshootingOperational ExcellenceTeamworkProcess Engineering

Technical Trainee, ACE Program

Aug 2020Sep 2021 · 1 yr 1 mo · Vishakhapatnam, Andhra Pradesh, India · On-site

  • 1. Successfully improved API yield and solvent recovery through protocol studies and data-driven analytics.
  • 2. Streamlined manufacturing operations by reducing Operator Muri activities, enhancing overall efficiency.
  • 3. Certified with a Lean Six Sigma Yellow Belt for my contributions to the Yield Improvement Project.

Ultratech cement

Summer Internship

Jun 2019Jul 2019 · 1 mo · Aditya Nagar Malkhed, Gulbarga · On-site

  • 1. Project: Velocity Profile in Pre-Heater
  • 2. Analyzed velocity distribution in a pre-heater system and developed dynamic Excel flow sheets with cyclone diagrams.
  • 3. Enabled temperature-based simulations to calculate performance metrics for each cyclone stage

Career development centre ( former placement & training dept), nitk

2 roles

Head Placement Coordinator

May 2019Aug 2020 · 1 yr 3 mos · On-site

  • 1. Head Placement Coordinator for 2019-2020 Batch of NITK.
  • 2. Achieved placement statistics of 97.2% for UG and 79.9% for PG, contributing to one of the most successful placement seasons at NITK.
  • 3. Led a team of 100+ student coordinators, coordinated with Placement Office staff, institute administration, and over 700 recruiting companies, ensuring seamless execution & successful of recruitment drives.
  • 4. Initiated and executed key activities including policy formulation (company & student), CDC branding, student coordinator hiring process, mentorship programs, and HOD engagement, streamlining placement operations.
  • 5. This role offered a transformative experience—shaping leadership, strategic thinking, and professional networking while building lifelong friendships and personal growth.

Internship Coordinator

May 2018Apr 2019 · 11 mos · On-site

  • 1. Internship Coordinator(IC) for 2019-2020 Batch of NITK.
  • 2. Acted as a key liaison between the Training & Placement Department and over 700 B.Tech students, ensuring smooth communication and coordination throughout the internship season.
  • 3. Successfully fulfilled responsibilities, including conducting online assessments, managing logistics, and providing top-tier hospitality to visiting recruitment teams.
  • 4. Facilitated internship/Placement drives for leading companies such as ExxonMobil, Wells Fargo, Morgan Stanley, Dr. Reddy's Laboratories, Edvizo Media, Amazon, and others.
  • 5. Strengthened campus-industry engagement by streamlining processes and enhancing the overall recruitment experience for both students and recruiters.

Mangalore chemicals and fertilizers limited

Internship Trainee

Dec 2018Dec 2018 · 0 mo · Panambur, Mangalore · On-site

  • 1. Safety training
  • 2. Refrigeration system at the Import Ammonia Terminal (IAT)
  • 3. Various field visits, including the Ammonia plant, Urea plant, other production units, bagging section, DM plant, and other utility facilities.

I-pac (indian political action committee)

Core Member

Jul 2018Jul 2020 · 2 yrs · NITK Surathkal · Remote

Bharat heavy electricals limited

Summer Intern

May 2018Jun 2018 · 1 mo · Bangalore · On-site

  • 1. Project: Optimizing Fuel Efficiency in Industrial Kilns and Furnaces.
  • 2. Case Study: High-Abrasion Ceramics in Industrial Piping Systems.

Internshala

Internshala Student Partner 8.0

Sep 2017Feb 2018 · 5 mos · National Institute of Technology Karnataka,surathkal · On-site

  • 1. Acted as a bridge between Internshala and students, guiding peers to discover internship opportunities with top companies across India.
  • 2. Organized and hosted multiple seminars, workshops, and campus events to raise awareness about Internshala’s offerings and empower students in their career journeys.
  • 3. Led impactful online and offline promotional campaigns to maximize student engagement and platform visibility.
  • 4. Recognized with the Internshala Trainings Gold Award for outstanding performance and contribution to student outreach

Reflux, nitk surathkal

Executive member l Marketing

Aug 2017Nov 2019 · 2 yrs 3 mos · National Institute of Technology,Karnataka · On-site

National cadet corps

Lance Corporal

Aug 2016Mar 2019 · 2 yrs 7 mos · NITK Surathkal, Manglore · On-site

  • 1. Rank: Lance Corporal.
  • 2. B & C Certificate Holder.
  • 3. Successfully executed assigned responsibilities throughout the training period, including drills, camps, and community service activities.

Education

National Institute of Technology Karnataka

Bachelor of Technology - BTech — Chemical Engineering

Jan 2016Jan 2020

Telangana Social Welfare Residencial Educational Institution Society Jr. College Chilkur, RR Dist

Intermediate MPC — Science

Jan 2014Jan 2016

Zilla Parishath High School, RR Dist, Telangana

Secondary School

Jan 2009Jan 2014

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