Gaurav Nayan Khandekar

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

Work Experience

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.
Accomplishments
  • 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.
Education
  • B. Tech, Electrical Engineering – College of Engineering Pune (COEP) | India | 2015–2019
Certification
  • Excel Skills for Business: Macquaire University
  • Business Writing: University of Colorado Boulder
  • Six Sigma Green Belt: KPMG
Extra-curricular
  • Profile Committee Member, PGPX 2026–27, IIM Ahmedabad – curate and present batch profiles to recruiters.