Resume - Rich17+yrs. experience in Project Management, detailing, execution, plant operat...

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Resume #15898

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JOB OBJECTIVE
Senior level assignments in Projects/operations Management in the Industrial Sector.

SUMMARY OF SKILLS & EXPERIENCE
Over 17 years of rich experience in Project/ Operations Management and in the Industrial Sector.
- Core competence in effective planing & scheduling to ensure procurement and execution of projects dealing with setting up the production facilities within time & budgetary parameters. Major projects handled are
- End to end execution of the project for setting up the Copper-II Project worth RS 250 crore(US $ 58 million) for production of 70000 TPA copper at Birla Copper
- End to end execution of the project for setting up the Copper-III Project worth RS 900 crore(US $ 208 million) for production of 250000 TPA copper at Birla Copper
- Executed & commissioned the Cu concentrate project at Birla Mount Gordon Australia.
- Continuous Cast copper rod project worth Rs. 90 crore (US $ 21 million) at Birla Copper.
- Project execution and maintenance of 3000TPD concentrate beneficiation plant for Lead and Zinc.
- Expertise in conceptualizing and implementing process modifications
- B.E. (Mech.) from University Of Rajasthan Jaipur with Diploma in Management from Indira Gandhi National Open University New Delhi.

KEY AREAS OF EXPERTISE
Project Management
- End to end execution of projects dealing with procurement, installation & commissioning of plant machinery & equipment.
- Detailed planning & scheduling to ensure execution of project within time & budgetary parameters.
- Effective site management & monitoring the progress of work in terms of cost, resource deployment, time over runs and quality compliance.

Process Engineering
- Designing internal controls & quality audit checks as well as process modifications for various operational to optimize resource utilization and enhance efficiency levels.
- Adapting target-based approach, TPM, TQM & 5S practices, reverse engineering & design improvements to optimize resource utilization and enhance productivity.

Operation & Maintenance
- Ensuring smooth operations to maximize production and to meet pre-set production targets.
- Planning & implementing effective preventive & corrective maintenance schedule to enhance equipment reliability & up time.

Materials Management
- Designing, implementing and monitoring effective procurement schedules along with finalising the specifications to ensure ready availability of materials.
- Handling project procurements along with target based negotiations.
- Developing cost effective indigenous import substitutes for imported machinery/spare parts.

Quality Assurance/ Trouble Shooting
- Ensuring complete in-process quality control and continuous improvement in process capabilities.
- Proactively identifying the areas of quality failure and taking appropriate corrective measures.

Commercial Operations
- Preparing technical & commercial offers/ proposals along with handling tender/ ordering/ contract/billing related formalities & documentation.

ORGANIZATIONAL EXPERIENCE
Since January 1996 with Hindalco Industries Limited Unit: Birla Copper.
(Birla Copper is having the distinction of being the worlds largest single location Copper smelter. I feel proud of being one of the key figures in this growth story.)

Career path within the company
Promoted to Deputy General Manger ( Projects) in April 2005
July 2003 to March 2005 Senior Manager (Projects)
From Oct. 2001-July 2003 Manager (Projects)
From July 1999 to March 2000 Head Of Mechanical Operations
From January 1996 to June 1999 Project In charge Dy. Manager / Asst. Manager

On Going Project ( Now under commissioning from 23 April 05)
- 2.5 Lac TPA Copper-III Project (Project worth Rs 900 crore or US $ 208 million) consisting of the following plants.
- 2.5 Lac TPA Smelter Technology Mitsubishi Materials Corporation Japan
- 1200 TPD Sulphuric Acid Plant – Monsanto USA technology
- 2.5 Lakh TPA Electrolytic Copper Refinery
- 1000 TPD Oxygen plant – Prax Air USA
- All the utilities such as WTP, EPT, DM plant, Propane, HFO and Naphtha facilities.

Other Projects Handled
Successfully executed & commissioned the following projects
- Project at Birla Mount Gordon Australia and Nifty mines Australia for producing 2.75 Lac MT/Year Copper concentrate, including Ore handling & crushing plant, Grinding section, Floatation section, Reagent section & thickeners, Tailing disposal section, Filtration plant.
- Copper-II Project(Worth RS 250 crore) for production of 70000 TPA copper based on Ausmelt technology form Australia and refinery is based on ISA process comprising the following plants
- 70000 TPA Copper smelter Ausmelt Australia technology
- 250TPD Oxygen Plant BOC technology
- 70000 TPA Copper Refinery
- 360 TPD Sulphuric Acid plant Monsanto USA technology
- Copper-I Expansion Project for enhancing the capacity of Copper Smelter plant from 1 Lac TPA to 1.8 lakh TPA. (Project worth Rs. 75 Cr. Or US $ 17 million)
- Continuous Cast copper rod project (Worth Rs. 90 crore) based on Southwire USA technology as Project in charge and commissioned the project in March 1997 prior to schedule and achieved rated capacity within three months and also secured ISO 9000 certification of the plant.

Achievements
- Achieved savings to the tune of Rs 55.56 Cr (US $ 13 million). through completion of Copper-1 expansion project in Rs.75.34 Cr.(US $ 17 million) against approved CP of Rs. 130 Cr (US $ 30 million)
- Successfully executed Copper-II Project at optimal cost of 250 Cr. As against industry norms of Rs. 700 Cr (US $ 161 million)
- Successfully adapted target-based approach viz., Questioning the need & specifications, Zero base costing, Indigenisation, On site fabrication i.e. non-turnkey concept, Limiting overseas assistance & Target based negotiations for optimizing resource utilization.
- Successfully developed cost effective Import substitutions/ indigenisation for
- Tuyere punching machine Copper expansion –I (Savings Rs.74 Lakh)
- Converter-3 completion (savings Rs.4 Cr or US $ 0.95 million)
- Polishing filter in refinery Copper Expansion-I (Savings Rs.72 Lakh or US $ 0.16 million)
- Tank house automatic crane (Savings worth Rs.18 Cr US $ 4.15)
- Cathode stripping machine indigenisation in Copper Expansion –II. (Savings Rs 13 Cr or US $ 3 million)
- Anode caster indigenisation in Copper Expansion –II. (savings worth Rs 25 crore)
- Saved Rs. Rs.2.68 Cr through developing Refinery tanks & piping packages
- Successfully implemented preventive & corrective maintenance schedule for the 1 lakh TPA smelter plant for effective maintenance of the plant.
- Executed several de-bottlenecking projects.
- Dryer Concentrate Feeding System.
- Process air and water Cooling system revamping.
- Successfully adapted TPM, TQM & 5S practices to enhance product quality and productivity and established the company as market leader for CC rods in national as well as international markets.
- Developed cost effective import substitutes for
- Steam Dryer and achieved savings worth Rs. 6 Cr ( US $ 1.38 million)
- Silver Refinery and achieved savings worth Rs. 1.75 Cr ( US $ 0.4 million)

From July 1991 to Dec 1995 with Hindustan Zinc Ltd. Udaipur as Sr. Engineer (Mech.)

Key Tasks Handled
- Played a key role in erection & commissioning of 600 Cr ( US $ 138 million). 3000 TPD beneficiation plant for lead & Zinc including Ore handling & crushing plant, Grinding section, Floatation section, Reagent section & thickeners, Tailing disposal section, Filter section consisting of LAROX pressure filters.
- Ensured effective maintenance of the plant for smooth operations and to maintain productivity and profitability.
- Successfully implemented process improvements and achieved above 95% availability of LAROX Finland Conc. pressure filters.
- Successful developed a 30 cub Mt floatation machine for improving metal recovery and reduction in tailing loss and achieved reduction in tailing (waste) Zinc losses from 2.5% to1.25% (improving Zinc recovery from 84% to 89%)
- Distinction of being awarded the 'Yashad Shree' the biggest award of the company.

From October 1990 to July 1991 with Tata Consulting Engineers Mumbai as Engineer (Mech.)
Key Tasks Handled
- Played a key role in designing Water, ETP, Ventilation & Air Conditioning Systems for various projects viz.,
- Nuclear Power Corporation Plant.
- Tata Electric Company A/C & ventilation projects.
- Tata Consultancy services
- Various municipal Water supply and ETP Projects

From Dec1987 to Sept 1990 with J.K.Synthetics Limited Kota as Astt. Engineer (Mech.).

Key Tasks Handled
- Handled effective maintenance of Polyester Staple Fiber Plant in Chemical section including Nitrogen plant, Compressed air plant, Air Conditioning & ventilation, Water Treatment Plant.

TRAINING
- Undergone training at Southwire USA & Morgan construction Company USA for one-month training & inspection.

CERTIFICATION
- Qualified Lead Auditors Course for Quality Management System of ISO 9002- 1994 from Allen Griffin Associates U.K. In 1998.

COMPUTER SKILLS
- Functional knowledge of MS window, MS project & Primavera project management package

EDUCATIONAL QUALIFICATION
- B.E. (Mech.) from University Of Rajasthan Jaipur in 1987.
- Diploma in Management from Indira Gandhi National Open University New Delhi in 1997.

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