Gaurav Nayan Khandekar
Operations and product development leader with 6.8 years at ITC Limited, with expertise in operational excellence, new product development and project management. Managed large unionized shop-floor teams and cross-functional projects that delivered operational excellence, digital transformation, process improvement, cost optimization and product commercialization. I developed an AI-based predictive quality model, which was replicated across manufacturing units, and led the end-to-end development of a nicotine-replacement product. I am assignee on 3 patents for product innovation. And I advanced shop-floor diversity by onboarding the division’s first 3 women operators.
Work Experience:
6.8 Years
Industry:
Consulting | FMCG & E-Commerce | Manufacturing & Engineering
Function:
General Management | Operations & Supply Chain | Project & Program Management
ITC Limited |Pune
Manager – Primary Manufacturing | ITC Limited | Pune Oct 2024 – Mar 2026
- Led manufacturing operations with 86 personnel across managerial, unionized and contractual workforce and delivered record 7,177 kg/hr throughput and highest annual output.
- Developed an AI-based predictive process model to optimize equipment set-points, which delivered a 12-year-high-quality score of 94.26% and reduced process variability by 77%. The solution was replicated across ITC units.
- Delivered ₹48.47 L cost savings through raw-material optimization, spare indigenization, in-house engineering and AMC contract extension at existing rates.
- Executed ₹95 L capacity-upgrade CAPEX and developed business cases for ₹3.2 Cr of upcoming investments.
- Coordinated Logistics, Procurement and Production for an 8-day shutdown. Aligned inventory pre-build and treatment of 1,400 T stock to ensure uninterrupted downstream supply.
- Managed union engagement with zero major IR issues and partnered with HR to onboard the division’s first 3 women shop-floor employees and co-develop a maternity policy.
- Achieved a division-high 95% EHS audit score with zero lost-time accidents and zero HACCP/cGMP recertification non-conformities.
Manager – Product Technology | ITC Limited | Bengaluru Jul 2023 – Sep 2024
- Directed end-to-end development of a nicotine-replacement product from market research and product benchmarking to prototyping and selection of 2 preferred flavours for commercial launch.
- Coordinated Marketing, Packaging, Manufacturing, Regulatory, Quality and external partners to build the scale-up supply chain and deliver product milestones on time.
- Developed 3 miniaturized heating systems with international technology partners (₹4 Cr) from product specifications through prototype testing and IP assessment.
- Executed ₹23 Cr CAPEX to build manufacturing, packing and testing capabilities, including a ₹7 Cr laser system and 7 million sticks/month prototyping capacity.
- Developed UAE and Nepal supply-chain plans across sourcing, cost assessment and local vendors. Identified overseas contract manufacturers for lower-cost local production
Assistant Manager – New Generation Products | ITC Limited | Bengaluru Feb 2022 – Jun 2023
- Served as single point of contact for global OEM/ODM partners across product evaluation, prototype development and supply-chain establishment for a new product category.
- Built an indigenous vendor base for machine refurbishment and modification, delivering ₹7 Cr one-time savings and reducing lead times versus overseas OEM sourcing.
- Refurbished and commissioned a prototyping line with 7 million sticks/month capacity to enable rapid product-development trials without external facilities.
- Managed daily pilot-plant operations with 6 Technical Associates and ensured timely delivery of samples for sensory and analytical evaluation.
- Identified the root cause of Bluetooth connectivity failures in a heating-system companion app and recommended hardware/software changes that were implemented.
Production Executive – Primary Manufacturing | ITC Limited | Munger Nov 2019 – Jan 2022
- Managed production shifts with 55 workers and external service providers and ensured uninterrupted supply to 2 downstream manufacturing units.
- Improved productivity by 4 personnel per shift through time-motion studies and workstation redesign and delivered ₹38.4 L annual savings through union LTA.
- Executed ₹3.5 Cr automation and digitisation projects across robotics, material handling and process controls.
- Established an end-to-end manufacturing process for a new product variant and expanded capacity 30times from 200 to 6,000 kg/day.
- Restructured shift operations with the union during COVID-19 to maximize constrained manpower and ensure uninterrupted supply.
- Named assignee on 3 ITC patents for product and technology innovations.
- Earned the ITC CEO Achievers Award for business continuity during COVID-19 and successful implementation of practices under the Long-Term Agreement.
- Won 1st Prize at the ITC Divisional Quality Competition (PACE 4.0) for consistent product quality across manufacturing shifts.
- Ranked among the Top 10 at the ITC National Supervisory Skills Competition for CO₂-based controlled fumigation as a sustainable alternative to phosphine.
- Earned Outstanding Rating (5/5) twice, ITC's highest performance rating, across manufacturing leadership roles at Pune and Munger.
- B. Tech, Electrical Engineering – College of Engineering Pune (COEP) | India | 2015–2019
- Excel Skills for Business: Macquaire University
- Business Writing: University of Colorado Boulder
- Six Sigma Green Belt: KPMG
- Profile Committee Member, PGPX 2026–27, IIM Ahmedabad – curate and present batch profiles to recruiters.