Resume - Maint Planning, Materials management, warehouse, plant maint, turnaround, projec...

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Resume #45268

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JOB OBJECTIVE
Seeking assignment in Maintenance Planning/ Costing & Budgeting /Field Maintenance/ Warehouse& Materials Management/Cost Saving Initiatives with a frontline manufacturing setup.

PROFESSIONAL PROFILE
- A Mechanical Engineer with over 18 years of rich experience in the Refinery, Petrochemical industries in the field of Plant Maintenance, Planning, Scheduling using MS Project soft ware, Primavera P3 V3.1, Budgeting, Cost Estimation, Monitoring, Contracts administration, Materials-Warehouse, Off-sites Tankages, Pipelines etc.
- Presently serving Kuwait National Petroleum Co. Kuwait (KNPC Refinery) as Engineer- Mechanical Maintenance thru contact basis since Jan-2005 ( Manpower Supply to KNPC).
- Keen Planner & executor with demonstrated abilities for Turnaround Planning, Shutdown planning activities, and improving plant safety, reliability and integrity playing vital role in a team with leadership skills.
- Proficiency in designing maintenance (preventive, predictive & systematic) strategies, procedures and methods; diagnosing breakdown problems; failure analysis, monitoring and controlling maintenance costs.
- Skilled at developing cost effective vendors for procuring materials, spares and consumables with efficient spare parts management and taking cost saving initiatives.
- Expertise in handling Maintenance of welding & Fabrication Shop, heavy equipment, Process units field maintenance which includes PM jobs, Trouble shooting, equipment overhauling, condition based maintenance, planned & emergency shutdown, Major Turnaround, Plant additions/modifications and fire protection &safety systems.
- An effective communicator with strong analytical, logical, problem solving & organizational abilities.

CORE COMPETENCIES
* Planning - Day to day & Turnaround
- Handling project activities involving working out various resource requirements with respect to spares, manpower, services, machineries, & monitoring overall project operations for ensuring timely completion.
- Managing resources to perform project activities in cost effective manner ensuring that site operations are carried out smoothly. Responsible for procuring and maintaining equipments for production.
- Functioning as an interface for coordinating with production departments to ensure that the production schedule is met and ensure on-time seamless delivery.
- Preparing M&R Budgets, long term plans & cost Estimation. Monitoring and analyzing capital expenses &operating expenses. Quantitative analysis of various maintenance expenditures.
- Developing commercial contracts and well acquainted with planning and scheduling software MS project, Primavera P3 V3.1.
- Directing & supervising Engineers and supervisors in maintenance related tasks. Reviewing day to day maximo work orders, co-ordination and planning for execution technical specification review etc.
- Participating in departmental review meetings, turnaround meeting for emergency shut down /planned shutdown in close co-ordination with operation.
- Executed major unit revamping projects with total responsibility till commissioning and equipment replacement in Refinery.

* Plant Maintenance
- Planning and effecting preventive maintenance schedules of various mechanical equipment to increase machine up time and equipment reliability.
- Proactively identify areas of obstruction/ breakdowns and take steps to rectify the equipments through application of trouble shooting tools.
- Executing cost saving & energy saving techniques/ measures and modifications to achieve substantial reduction in O&M expenditures and work within the budget.
- Carrying out Equipment maintenance as per PM schedules, equipment trouble shooting Spares arrangement, co-ordination with inspection, operation etc.
- Updating the system as per CMMS requirement and generates MIS Reports.

* Safety & Quality Assurance
- Establishing quality standards & implementing control systems to enhance quality of maintenance work.
- Monitoring shop production/out put, keeping control over shop floor activities ensuring smooth plant operations. Executing 5S QC tools for engineering and working towards zero defects by implementing SQC.
- Conducting Safety Audits and ensuring compliance to QS 9000, ISO 9001: 2000 & Kaizen safety standards.
- Compliance to company safety policies, standards and creating awareness among work force for achieving zero accident goal at work place.

* Warehouse & Spare Parts Management
- Managing spare parts quotation conformation & receiving spare parts, invoice & conformation.
- Planning & procuring of maintenance spares based on consumption pattern reducing spare cost by doing Kaizens. Carrying out ¡* why-why analysis¡¨ for breakdowns & Kaizens to avoid them in future.
- Governing the inventory function of spares involving planning for storage and use of material so as to improve storage conditions and reduce expenses & wastages to minimum.
- Preparing purchase specifications for procurement of materials/equipment required for turnaround updating the system /CMMS as per ISO 9001 quality policy.

* Vendor Development/Contract Management
- Identifying & developing cost effective vendor/supplier base for cost effective procurement of materials, spares and consumables & optimizing inventory hold up.
- Preparing Annual Rate Contracts with vendors for stockable items and for work order indents and timely renewal of contracts after complete review.
- Certifying jobs carried out by contractor & processing the bills submitted by them as per contact requirement.
- Arranging necessary inspection facilities for Reliability based Inspection on plant equipment (RBI) Receipt of Inspection reports, review and updating the system.
- Processing all contractor invoices, bills, and claims, made change orders as required, and co-ordination with finance for clarifying the payment related queries.

* Plant Enhancement & Cost Saving Initiatives
- Identifying areas of improvement and recommending process modifications and equipment calibrations to enhance operational efficiencies of the systems.
- Reviewing the operational practices, identify the areas of obstruction/ quality failures and work on system and process changes for qualitative improvement/ energy conservation.
- Undertaking Value-Engineering initiatives at the suppliers end to reduce cost of rejection of material supplied.
- Supervising the preparation of MIS and various other reports to apprise top management of the routine engineering operations and assist in critical decision-making.

ORGANISATIONAL EXPERIENCE
Since Jan'05 with Kuwait National Co. Kuwait (KNPC Refinery) as Engineer- Mechanical Maintenance.

SIGNIFICANT ACHIEVEMENTS
- Presently working in KNPC Refinery and responsible for Units Maintenance, off-site storage Tankages, Pipelines.
- Handled/executed two major unit shutdowns (Coker unit) in May-2005 and June 2006 and completed with in time and safely.
- KNPC Certified /Authorised safety Observer (BBS Observer) Behaviour based safety. New concept being followed to promote safety awareness in refinery.
- Handled major piping modification job in far-site area for augmenting Sea port loading facility.
- Received letter of appreciation for timely completion of job with minimum down time thereby saving cost to co.
- Member of SHE committee (Safety, Health & Environment) for the Refinery Units and conducting regular safety audit and generating reports to the management with in put suggestion for safety improvement.

Apr'03 to Jul'03 with Saudi European Petrochemical Company, KSA as Maintenance Planning Engineer.
Petrochemical Industry (Poly Propylene& MTBE Units) Turnaround Planning. Carried out planning of work orders for turnaround jobs. Material planning, scheduling in MS Project. Maint software used MMS.

Significant Achievements
- Participated in various shutdown review meetings and implemented the decisions in planning.
- Developed the safety plans for specific work orders and updated MMS system.
- Prepared the turnaround/ shut down plans, of bar chart, schedule, manpower allocation in MS Projects/primavera P3 Ver3.1.
- Handled PP unit S/D Planning and material procurement.
- Managed a team of 2 field engineers and one planning assistant, 2 foreman, and 3 fitters.

1988 to 2005 with HPCL Refinery - (Fuels & Lubes), Mumbai - India.

CAREER GROWTH PATH WITH SIGNIFICANT ACHIEVEMENTS:
* As Manager Plant Maintenance (2001 to Jan'05).
- Handled planning, directing and controlling all maintenance activities of assigned units i.e Units such as ATK Merox, Crack LPG, Hexane, Diesel Unionising unit (DUU), SRU Sulphur Recovery Unit, Hydrogen Generation unit, cooling tower, Co Boiler and utility plant.
- Identified the employees training needs and organized specific training for the section to ensure technological up gradation as per latest industrial standard.
- Work order control in Maint software Maximo (CMMS). Administration of maintenance contract works with the Implementation of Company Quality, Safety, Health, and environmental policies and implemented management decision at floor level.

* As Dy. Manager- Planning (1998- 2001).
- Reviewed and consolidated CMMS work orders and segregated as per priority and nature of job. Scheduled the work orders with available resources in co-ordination with field engineers and associated departments
- Prepared M&R Budgets for the Dept Shutdown/Turnaround Monitoring with MS PROJECT, PRIMA VERA P3 V 3.1 softwares.
- Prepared Turnaround Plans, bar chart, schedules, and cost estimation, and major equipment procurement.
- Involved in the Turnaround execution and status monitoring. Continuous review of progress and resource re-allocation for expediting the timely completion. Generated MIS for management appraisal and Records.

* As Deputy Manager-Warehouse (1994- 1997).
- Involved in Material Procurement, Issue, Perpetual Inventory Control, Warehouse Modernization, records and control, compliance to ISO Norms in warehouse functioning and Safety Plans implementation.
- Spearheaded the TQM Task Force & implemented ISO-14001 and TQM in warehouse.
- Procured spares and materials for Refinery maintenance and project work with 3 warehouse officers, 15 clerical staffs 10 contract workmen in co-ordination with local Indian suppliers and international suppliers.
- Purchased materials for shutdown and turnaround jobs and maintained warehouse having 22000 items and managed materials issue /receipts function in Computerised Materials Management system.
- Played key role in warehouse and implemented new stock set up/facility for new unit (Lube Refinery Expansion-II project- added 5000 items in stock).
- Also played leadership role in warehouse and motivated all employees and bagged Refinery Prestigious award ¡* Refinery best kept Unit¡¨ for warehouse unit for 3 consecutive years 1995, 1996, 1997. Got appreciation for customer satisfaction oriented service in warehouse.
- Initiated action for inventory reduction such as slow moving/non-moving items review, local development for import substitute, planning EOQ & re-order interval, storage of spares at supplier Go down & adopting JIT concept etc.
- Functioned as a Lead Member in inventory reduction task force committees.

* As Sr. Engineer Field Maintenance (1992- 1993).
- Led the Process Units Maintenance -Preventive maintenance, trouble shooting, Condition based maintenance of equipment in Refinery units for units such as Crude unit, ATF Merox, Vacuum Unit, Food Grade Hexane Unit, Fluidized Catalytic Cracking Unit (FCCU) etc.

* As Maintenance Engineer-Off-Site Tanks & Pipelines (1990- 1991).
- Handled the maintenance of Petroleum Products Storage Tanks& Pipelines, structural fabrication and erection (Off-Sites/Terminal). Time based maintenance and repairs based on inspection advise.
- Maintained the complete piping network in off site Refinery in co-ordination with inspection dept, operation and engineering dept.
- Carried out maintenance of storage tanks such as fixed roof, floating roof, tanks as per API standards.
- Maintained the mechanical facility of LPG storage system consisting of pipelines, spheres, LPG bullets, structural, MOV, valves fire fighting system &facilities etc.

* As Maintenance Engineer - LPG Filling Plant & Fab. Shops (1988- 1989).
- Carried out Maintenance the LPG Filling Plant Equipment, Workshop (Fabrication shop, Valves & Exchanger shop, Safety valves, welding and repairs on Refinery equipment at shop as well as at site.
- Developed PM schedules and implemented to keep Plant break down at zero level.
Technical Purview
Refinery Process Units: Worked in the field of maintenance in units such as Crude Distillation (APS/CDU), Vacuum Rerun, (VPS/VDU), Sulphur recovery, (SRU), Hydrogen Generation, Crack LPG, ATF Merox, Hexane, FCCU, propane, Coker etc. Terminal operation, Port loading facilities, Inter Refinery Transfers pipelines etc.

EQUIPMENT HANDLED: Refinery Process unit equipment, asphalt filling plant equipment, LPG storage facilities, NGL handling facilities, air/gas compressors, pumps, turbines, gear box, and static equipment such as Heat Exchangers, coolers, condensers, reformer, regenerators, reactors, heaters, towers (columns), vessel, Fin fan coolers, coke drums, fire fighting facilities, coke handling conveyors, coke ship loading facilities,, Hydro carbon &utilities pipelines, Petroleum products storage tanks, propane & LPG storage spheres, waste water treatment plant, API separator etc.

LPG Filling Plant Machinery: LPG Filling Carousel, cylinder conveyor system, LPG storage spheres, compressors, pumps, gear box, evacuation compressors, Air compressors, air dryers, pipelines, Remote operated valves, gas leak detection system, deluge valve system, fire fighting facilities & net work, etc. Also carried out repair/reclamation equipment spares, valve refurbishment, valve testing, repair of exchanger component/ pump spares etc.

TRAININGS ATTENDED
* Primavera Project Planner P3 v3.1 from KLG SYSTEL, MUMBAI- (PRIMAVERA USA Authorised Institute)
* CMMS/Maximo Latest version (Played Maximo roles as planner, executor and as an Approver (Manager) - Trained by HPCL in 1999 and using till date.
* Certified Reliability Engineer from Centre for Reliability, Chennai, India, Govt of India.
* Reliability Engineer thru Hoffincon Reliability Maintenance Management Institute, Chennai, India
* Welding Technology - Advani Orlekon Ltd, Mumbai, India
* Pipeline and its Corrosion - CECRI -Karaikudi, Tamil Nadu, India
* Inventory & Cost Control -HP Management Development Institute, Pune, India.

IT/COMPUTER SKILLS
- Familiar and well conversant in using International Codes and Engg Standards, viz as ASTM, ANSI, ASME, API, ISO, DIN, BS, SHELL DEP, AWS etc.
- Having through knowledge in Computerized Maintenance Management Systems MMS, CMMS, MAXIMO (Equivalent to SAP), MS PROJECT, Prima vera P3 Ver 3.1.
- Well versed with MS office application software- MS Word, Excel, Power Point, Lotus smart suit, Lotus Notes, Novel group wise, Outlook express, internet, email, etc.

ACADEMIC CREDENTIALS
B.E (Mechanical) from Madras University in 1987.

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