Resume - A Metallurgical Engineer with over 2 years of experience in Process management, ...

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PROFESSIONAL PROFILE

A Metallurgical Engineer with over 2 years of experience in Process management, Smelter Operations, Production planning, Quality Assurance. At present, associated with Sterlite Industries India Ltd, serving as Process Engineer- Primary Smelter with ISA smelt Technology. Expertise in handling the complete Primary smelter operations and entailing production planning, resource utilization, Coordination and communication with secondary smelter & manpower management. Proven ability in swift ramp of the process to achieve production targets with cost control & process parameters as per Standard Operating Procedure(SOP). Managed a wide spectrum of ISA furnace de-bricking and relining, major modification and improvements projects during major shut down, curtailing the shut down costs & expenses in stipulated time duration as per the plan. Adept at smelter operations with demonstrated abilities in working on Process parameters, initiatives, thereby enhancing Process quality and achieving annual throughputs, production & costs savings. Familiar with world class Quality, Safety and Environment Management systems like OSHAS, ISO 14001 and ISO 2001, TPM, 5S. An effective team leader with excellent relationship management skills, strong analytical, problem solving and organizational abilities.

ORGANISATIONAL EXPERIENCE

Serving since June 2007 for Sterlite Industries India Ltd as Process Engineer- Primary Smelter with ISA smelt technology.
KEY RESPONSIBILITES HANDLED
Process management/planning and Execution
„Ã Planning, scoping, estimation, tracking & making blend for production of copper within preset process constraints, process parameters within the budgets and deadlines.
„Ã Coordinating with Secondary smelter for ensuring no lapse in production by adhering to production planning, with 100% safety, concern for environment with excellent communication.
„Ã Preparing and reviewing RCAT (Root Cause Analysis Report) of any problem occurred in the process and to have a case study and to take control measures.
„Ã Organizing Brain Storming session with employees to have a common pool of knowledge on process related issue and gathering their innovative ideas for its solution
„Ã Discussing the Process Control Report of 24hrs and scrutinize for any deviations in Process parameters to ensure the plant and process performance are at its best.
„Ã Reviewing SIC (Shift In-Charge) Report everyday for production, feed reduction in the process, equipment break down and major communications.
„Ã Perfectly planning for shutdown and making a detailed job plan with duration for the job, responsibility, manpower required and resources availability.
„Ã Executing cost saving and energy saving techniques/ measures and modifications to achieve substantial reduction in O&M expenditures and work within the budget.
„Ã Coordinating material/ spare parts planning related activities encompassing identification of vendors, requirement specification & offer evaluation.
„Ã Proactively identify areas of obstruction/ bottlenecks in copper smelting process and take steps to rectify the same through application of trouble shooting tools.
Plant Operations
„Ã Overseeing plant operations encompassing ISA smelt operation, Rotory holding furnace and feed preparation, Waste heat recovery Boiler, material planning & store and other allied functions for accomplishment of overall business targets.
„Ã Handling plant operations including safe start-up, operation and shutdown of plant, trouble shooting and routine maintenance during shifts and proper planning for shut down and completing it in time efficiently.
„Ã Developing new process concepts and SOPs for production optimization yield improvement as well as handling quality initiatives etc.
„Ã Constantly tracking and reviewing the plant and process performance and taking necessary actions to solve it and studying its root cause to eliminate its recurrence.
„Ã Observing process parameters for any deviations or abnormalities and taking effective timely decision, investigating it and trouble shooting it technically.
„Ã Establishing quality standards, implementing stringent quality control systems to enhance quality and reduce rejection level.
„Ã Generating new innovative ideas for better process control, cost reduction, Equipment availability, safety, CDM (Clean development Mechanism), Environment.
Installation & Commissioning
„Ã Handling installation and commissioning of plants as well as handling facilities for completion of projects in stipulated time/cost parameters.
„Ã Undertaking up gradation, renovation & modification job of the existing manufacturing facilities of the plant.

Quality/ Safety
„Ã Maintaining quality standards, ensuring stringent adherence to quality standards, norms & practices, identifying gaps & taking corrective / preventive action
„Ã Ensuring strict adherence to OHSAS 18001 systems & procedures.
„Ã Charting several safety measures for minimizing occurrence of accidents, fires, calamities; conducting investigations for determining the cause of industrial accidents.
Team Management
„Ã Leading, motivating and training the employees to improve their operational efficiency.
„Ã Organizing training internal/external programmes based on the training need analysis to elevate the skills & productivity of employees.
„Ã Mentoring and motivating the employees to increase their operational efficiency
Noteworthy Credits
„Ã Innovative ideas implemented o Best implementable idea award by "Project Parivardhan 2008".
o Additional vibrofeeder to eliminate lumps in the concentrate and maintaining proper smelting.
o Controlled spillages and fly over of concentrates by chute modifications, increased recovery o Avoided wrong loading of Concentrates by creating interlocks in DCS of conveyors.
o Increased the oxygen pressure in oxy-LPG burner and reduced LPG consumption.
o Installed flow meter and level sensors in RHF spray ponds and hence controlled water level.

„Ã Pivotal in successfully executing the following improvement projects for de-bottlenecking and reducing the mean time between failures o Installation of Paddle mixer for ISA smelter feed preparation o Increased the conveyors trough angles and reduced the concentrate spillages o Changed Rotory holding furnace's Slag and Matte spout with Copper block and improved its efficiency o Changed ISA and RHF bricks with better grades for Increased Temperature operation.
o Increased ISA furnace campaign life from 20 to 24months o Additional bath block fixing inside ISA furnace for effective cooling for Refractory bricks o Additional Cascade cooling over the ISA furnace shell for protecting the refractory bricks from outside the furnace.

„Ã Fundamental in handling the following activities o Bagged best Shift In-Charge award, for shift activities o Production planning, shutdown planning, Job plan o Process management, Boiler operations, water quality assurance o Formulation of Maintenance procedures, planning & scheduling, check listing, Documentation.
o Implementation of 5s, effective implementation of step zero

„Ã Significant contribution in implementing the following o Various new technologies viz SAP R/3, TPM, CDM, TQM & 5S implementation, o Significantly contributed for reduction in copper loss o Increased the copper recovery to 98.5%
o TQM on reducing oil consumption in RHF by replacing oil burner with OFB.

ACADEMIC CREDENTIALS
„Ã B.E (Metallurgical Engineering) from Government College of Engineering, Salem.
„Ã Secured university 8th Rank in Metallurgy department in Anna University
„Ã Secured school 1nd Rank in XII standard, State Board
„Ã Secured school 2nd Rank in X Standard, Matriculation Board
TRAININGS AND KNOWLEDGE SHARING
„Ã Participated in 12th International Conference on Non-Ferrous metals and minerals
„Ã Training on fire fighting in industries
„Ã Training on Safety and work permit issue
„Ã Training on First aid
„Ã Training on DCS (Distributed Control Systems)
„Ã Training on Basic of Instrumentation and Controls
„Ã Training on SAP R/3
„Ã Training program on Self Discovery
„Ã Training on Basic leadership program
„Ã Training on SLF (Secured land fills) on Environments
„Ã Training on Risk Assessment by British safety council
„Ã Training in Computer usage - MS Office and Advanced Excel.

KNOWLEDGE PREVIEW
„Ã Quality systems, EMPs, OHMPs and 5S Practices.
„Ã Material management systems
„Ã MS Project- for the all Planning activities.
„Ã Windows based utilities like, Power point, MS ¡V Excel, Word etc.
„Ã Total Productive Maintenance (TPM)
„Ã Total Quality Management (TQM)

PERSONAL DETAILS
Nationality: Indian
Date of Birth: 29th April 1985
Age: 23years
Sex: Male
Languages: English, Tamil

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