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- 1. Experienced in Project Management, Maintenance & Operations, Troubleshooting, Training, Asset & Risk management and handling Insurance claim CAREER DIGEST A Mechanical Engineering back ground with 27 Years experience in Project Management entailing Maintenance / Troubleshooting, Operations and Team Management in Chemical Process Plant & coal fired co- Generation Plant. Currently associated with MCC PTA India Corp. Pvt. Ltd., Haldia, W. Bengal as Sr. Manager (Engineering). A keen strategist & implementer aiming at achieving timely project completion, profit and business growth objectives & turnaround for increase top line and bottom line in rapid change environments. Proficiency in managing maintenance of various equipments for reducing downtime and enhancing operational effectiveness of equipment. Effectively conceptualized and completed various operations pertaining to maintenance repair and modification and up-keeping of various process equipments. Honed skills in taking initiatives for reduction in costs by minimising equipment breakdown and improving productivity by technology management. Demonstrated excellence in setting priorities, develop a work schedule, monitor progress towards goals, and track details/data/information/activities. Expertise in managing various operations as per the set parameters & standards as well as experience of developing procedures for operational excellence. Played a vital role in problem diagnosis as well as repairing the failures of equipment. An effective communicator with excellent skills in building relationships. Possess strong analytical, problem solving and organizational abilities. An effective technical support for plant Insurance renewal & claim settlement ORGANISATIONAL SCAN Since May’99 MCC PTA India Corp. Pvt. Ltd., Haldia, W. Bengal (Member of Mitsubishi Chemical Holding Group, Japan) Key Deliverables: Project Management Managing activities right from the conceptualization stage to the execution; involving finalization of technical specifications, store management & inventory control, scheduling, progress monitoring, site management and manpower planning. Establishing project review, monitoring and status reporting procedures to accurately report progress of the project to the stakeholders and end user clients. Handling activities involving working out various requirements & monitoring overall project ope rations for ensuring timely completion. Managing the manpower, resources, inventory, and infrastructures as well as budgets for the area of operations within the department. Coordinating projects for the set up standards with accountability for strategic utilisation & deployment of available resources to achieve organisational objectives. Monitoring the activity at sites and review of project schedule, ensuring cost control within budget, planning for cash flow requirements, etc. Maintenance / Troubleshooting Planning and effecting predictive & preventive maintenance schedules for various equipment to increase machine up time & equipment reliability. Trouble cause analysis & implementation of countermeasures on time bound schedule Implementing maintenance schedules and carrying out periodic checks to ensure performance of various equipments and maintaining requisite documents for the same. Identifying areas of bottlenecks / breakdowns and taking steps to rectify the equipments through application of trouble shooting tools like root cause analysis. Maintaining and ensuring stringent adherence to quality standards, norms & practices, identifying gaps and taking corrective action. Overhauling / repairing of rotary equipment like pumps, compressors, decanters, gearboxes, blowers, agitators, rotary valves, rotary kiln/dryer & various conveyors like flight & bucket conveyors etc. Maintenance & trouble shooting of heavy fuel operated engine (5 & 6 MW each) having total capacity of 49 MW
- 2. Ensuring maintenance and stable operation of the plant at optimum cost by various motivation scheme like best performer award, Best Kizen (small improvement in ones own work area), best near miss incident reporting, best Quality circle activity etc. Scheduling repairs & testing of bulk material handling equipment, cranes, lifting tools & tackles, pressure vessels, tanks, Boilers, safety valves etc. Maintaining workshop equipment like turning, milling, drilling m/c, hydraulic devices, tool room & various maintenance consumables. Training on basic maintenance philosophy, regular check & corrective measures, enhance knowledge on handling equipment & tools etc. to a core group maintenance & operation. Sourcing & Procurement Directing the development and implementation of key purchase/ procurement strategies, contingency plans and ensuring that plans are aligned with production requirements. Budgeting and material requirement planning using forecast based planning for procurement and sourcing of materials ensuring optimum utilization of materials & maximum cost savings. Designing, implementing & monitoring effective procurement schedules along with finalising specifications of materials & establishing quality & quantity limits for effective inventory control. Managing the inventory levels & avoiding stock outs for different category. Process Enhancement Identifying scope for: - Planning & implementing technological changes to enhance productivity. - Modifications in equipments, process flow, working practices, consumables, power, etc. for controlling & reducing conversion cost per unit produced. Implementing various techniques for cycle time reduction, entailing identification of opportunities, energy audits, analysis of data, conduction of tests and implementation & post audits. Team Management Leading, mentoring & monitoring the performance of the team members to ensure efficiency in process operations and meeting of individual & group targets. Creating and sustaining a dynamic environment that fosters development opportunities and motivates high performance amongst team members. Notable Attainments: Significantly prepared project specification for equipment (rotary & static), plant, pipeline, etc. as per national or international standard like IS, ASME, ANSI, API, ASTM, etc. & statutory rules & guideline like OISD, TAC, IBR, Petroleum rule, Factories rule, etc. Prepared maintenance Budget & line of actions to achieve the targets / budget. Conducted Technical seminars to update & enhance technical knowledge of subordinates and workers. Co-coordinated, implemented & maintained QEH&S management system ISO-9001-2008, ISO-14001-2004 & OHSAS-18001-2007. Composed safety manual to guide people about right approach towards maintenance & construction activity in process plant. Effectively implemented the inspection interval of critical process equipment by ranking them as per reliability, productivity, safety & regulation. Fire fighting system augmented to receive maximum discount on premium of fire insurance . Tank inspection, evaluation & repairing process streamlined. Construction & maintenance of tanks, pipeline for transporting petroleum product from port to plant. Waste water sludge drying facility to reduce sludge volume to one tenth. Introduction of plate heat exchanger in place of induced draft cooling tower for process wasted water cooling. In service line hook up by hot tapping & stopple for 18” para-Xylene line at Haldia oil jetty Knowledge & Technical backup for Risk survey, Plant Insurance renewal & claim settlement PREVIOUS ASSIGNMENTS Apr’89 to May’99 Indian Aluminium Co. Ltd., Muri, Ranchi Major achievements Retrofitting of boilers, Expansion of coal & ash handling system, modification of steam headers Installation & maintenance of water purification system Development of indigenous spares for imported & aged equipment. Maintenance & trouble shooting of Boilers, Steam turbines, Compressors, coal handling plant, ash handling plant, condensate & feed water pump etc.
- 3. Experience in PTA Plant: Major equipment used are: 1. Pressure vessel,Tower,Tanks 2. Agitators,gearboxes,mechanical seals,screw conveyors,flightconveyors,blowers 3. Centrifugal Compressortrain(Motor,steamturbine &off gas expanderare usedasprime mover) 4. Varioustypesof pumps,filters,decanter,scrubbers,dryers,vibratingsieves 5. Huge applicationof heatexchangers(Shell /tube &plate type),coolingtowers 6. Hydrogengenerator 7. Hot oil heaters 8. Pipeline,valves 9. Productsilo& fillingmachine 10. MOC usedas SS-304,304L, 316, 316L,317L, Titanium, Duplexsteel,HastealloyandCarbonsteel Utility required: 1. Power 2. Water treatmentplant 3. Plant& Instrumentair 4. Nitrogengenerator 5. Waste water treatmentplant 6. Huge tank firmfor Px,Aceticacid,Methanol,NaOHetc. Maintenance feature & concern: Due to use of highly toxic & corrosive chemical like Acetic acid, HBr etc. corrosion is one of the major threats. An experience team of maintenance can only handle such plant. A well defined maintenance philosophy shall be worked out to upkeep the health of equipment. Major maintenance attributes are: 1. Maintenance philosophy – a) Equipmentratingbasedonsafety,productivity,reliability b) Maintenance schedule,Inspectionteam c) Skilledmanpower d) Conditionmonitoring, dailypatrolling,vibration&lubrication/greasing e) Spare parts management f) Training& continuousimprovement 2. Planningco-ordination: a) Technical service teamforproperplanning&communicationamongprocess&engineeringgroup b) Regularinvestmentplanforreplacementequipment&installationof new facility c) Budget& cost analysis d) Fix up medium&longtermplan e) Promotionof safety f) Maintainrecords& documentation g) Shutdownplanning h) Qualitycontrol & reviewresults i) Compliance &obeyregulation 3. Resource development: a) Developsub-contractorcapability b) Reliable source forconsumables c) Sourcesfor shorttermrental of maintenance equipment d) Developmentof vendorforsupportatcrisis e) Training to develop skill of potential candidate as a successor