Resume - I have over 35 year's experience in the Cement Industry, Machinery Manufacture, ...

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Resume #4444

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Application for –
Unit Head/ Corporate Positions/ Consultancy Assignments - Cement or Heavy Process Industry/ Machinery manufacture/ Construction Projects

BRIEF BIO-DATA
Experience:

1996- to date (current/ last employer) Andhra Cements Limited

As Vice President (Works) having overall charge of Plant Operations and all related activities for smooth operation of the large 1.0 Million Tonne per Annum capacity plant of FLS, Denmark, design and supply, located at Dachepalli.

Since July, 2003, I had been transferred to the HO of the Company at Hyderabad, with overall charge of the Operations' function for 2 factories, the one at Dachepalli and the other located at Vishakapatnam. In addition, also having charge of the Purchase Department at the HO. I retired from this Company on 31-10-2003.

Specific Targets

# Achieving Rated production levels.
# Identifying areas for improvement and updation/ retrofitting of specific equipment for improving plant efficiency - as small scale projects.
# Developing good Industrial Relations, hitherto sadly lacking.
# Uplifting Employee morale at all levels.
# Preparation of Project Report for capacity expansion from 3000 TPD to 4500 TPD clinker production. This is pending top management sanction and presently held in abeyance, in view of surplus market conditions in the State and most parts of the country.
# Developing and maintaining good relations with the local leaders in the neighbouring villages, hitherto sadly lacking.
# Optimum operation and utilisation of Captive Power Generation.

Major Achievements

# Improved the quality and consistency of clinker production from the Kiln from meagre levels to the Rated Capacity of 3000 TPD. In fact the kiln now produces +3200 TPD clinker without any strain.
# Brought down Fuel Consumption from 970 K. Cal per Kg of Clinker to 790-805 K.Cal per Kg of clinker, without any investment.
# Brought down power consumption from 143 Kwh/ MT of cement to 92 Kwh/ MT on OPC basis, with a very minor investment.
# Improvement in operation of cement grinding mills – increased output
Mill No. 1 48-50 TPH to 55-58 TPH (on OPC Basis)
Mill No. 2 72-75 TPH to 88-92 TPH (on OPC basis)
# Optimising the chamber lengths and the grinding media charge in the Mills for substantially improved performance even at higher levels of fineness and even in open circuit operation. This has resulted in a major saving in power consumption.
# Improvement in Vertical Roller Mill and Ball Mill operation for Raw meal grinding - now yielding much higher outputs,
Ball Mill 95 TPH to 115 TPH
VRM 170 TPH to +200 TPH
# Stress on human-relations, resulting in much higher confidence levels among all employees and vastly improved Industrial Relations.
# Training of personnel at all levels for improving productivity & committment.
# Highest Utilisation level of Packing Machines in the whole of the Cement Industry in India. Achieving a consistent packing rate of +2,700 TPD with only 2 nos. L&T RC-12 series Rotary packers, even though despatch requirement is for 3 grades of cement (OPC Gr. 53 and 43 as well as PPC). This is un-paralleled in the cement industry in the country.
# Improvement in Captive Power generation from 3.4 Units to 4.05 Units per litre of HFO.
# Developed a comprehensive Expansion Plan, along with equipment selection and tentative layout, for achieving Clinker Production of 4,500 TPD and cement production of 3,500 TPD/ This includes the installation of (1) 1200 TPH Crushing Plant for Limestone, (2) Stacker-Reclaimer of capacity 2 x 30,000 MT, (3) Modification for up-gradation of Vertical Mill for Raw meal, (4) Mechanical Handling and Transport of Raw meal and Kiln Feed systems to replace Pneumatic handling, (5) Replacement of Pre-heater cyclones with Low-Pressure cyclones, (6) Replacment or retrofitting of all major Kiln Fans for higher efficiency, (7) Increasing the speed of the Rotary Kiln from 3.1 to 4.2 RPM for achieving the higher through-put of 4,500 TPD, (8) Retrofit of Grate-Cooler with IKN KIDS, (9) Clinker handling system and additional storage of 30,000 MT, (10) Coal handling and blending facilities, (11) Facilities for pre-crushing of Clinker and optimizing chambers/ load of Cement Mills, (12) One additional cement storage silo of 10,000 MT capacity, (13) 150 TPH capacity Electronic Packing machine with auxilliaries, (14) Truck Loading machine for packed bags, (15) Railway line for coal rakes and likely cement rakes, in future, for movement by rail.
# Reduced the manpower in worker category by about 12% and in Managerial/ officer category by about 15%.

# The factory obtained ISO-9002-1994 accreditation under my stewardship in August, 1999. Now upgraded and obtained ISO-9001-2000, in November, 2002. I am the designated MR (Management Representative) for implementation of ISO on a company-wide basis and designated Chief Executive on specific delegation by the Managing Director.
# Development of a comprehensive MIS, with targets, performance indices and actual performance on a month to month basis and for easy comparison with earlier years. The MIS includes data on material consumption, material costs, other input costs, equipment and manpower utilisation, standard deviation from internal Quality norms, etc.

1995-96 Shiva Medicare Limited

As Chief Executive, for the 100% EOU, manufacturing Latex Examination Gloves for export to USA. Reporting to the Chairman-cum-Managing Director/ Executive Directpr, both based at New Delhi. The factory was located in the EPZ at Chennai.

I had the overall charge of the factory for Production, Quality Control as per International norms, Installation and commissioning of new equipment like Manufacturing lines imported from Malaysia, Thermic Fluid heating boilers, Modifications to Steam Boilers, material and product handling systems, Finance (liaison with bankers), handling of Imports and Exports.

1992-94 Khaitan Hostombe Spinels Limited

As Vice President, having independent charge of the North India Operations of the Company. Based at Lucknow, with overall responsibility for 2 operating factories in the Hill Districts of Uttar Pradesh and a 3rd unit under construction near Bareilly, for manufacture of DBM (Dead Burnt Magnesite) for the Steel Industry and large foundries. Reporting to the Managing Director based at Kolkata.

Operations – Complete responsibility of the Operating Plants. The respective Plant managers of both locations reporting to me. Production levels and realisation improved by about 30 % from earlier levels.
Projects – Independent charge of the new plant under construction, near Bareilly for manufacture of DBM by the Rotary Kin Process. Management of a large construction work force, finalising equipment selection from various suppliers, interaction on weekly basis with the project consultants for layouts and facilities required to be provided.
Contracts – Identification of suitable and reliable agencies, negotiations, control of erection and transport contracts.

Marketing – Marketing of DBM in North India with the assistance of independent agencies and customer servicing/ guidance in applications.
Accounts – Directly responsible for the profitability of and self sufficiency of the two operating plants, liaising with Bankers at 3 locations for credits and bill discounting, etc.
Industrial Relations – This was under my charge for al the 3 units, was drastically improved and maintained.
Liaison – As required, from time to time, with the State Government of U.P., Statutory bodies, Administrative matters and Public Relations.

1967-1992 The Associated Cement Companies Limited

Joined this premier Cement Company in August, 1967, after Graduation, as a result of selection through campus interview. Joined as Junior Engineer and worked in various capacities and at various locations of the Company and rose to the level of General Manager (Unit Head).

Operations – Worked in Wet Process/ Semi wet Process/ Semi Dry-Process/ Dry Process plants, Refractories' Manufacture, Machinery Manufacture at different locations and at different levels.
Projects - Construction and comissioning of large projects, involving large concrete and fabricated structures, prefabrication of structures and components of equipment for installation at site, heavy process equipment manufacture and installation, installation of bought-outs like electric drive motors, gearboxes and machinery of various types, provision of plant services like, compressors, pumps, Electrical Sub-stations and distribution of power, Electronic and PLC control systems, site instrumentation, etc.
Industrial Engineering – Manpower Studies, Work and Method studies carried out at various locations of the Company for efficiency improvement, utilisation of waste materials and Cost & Manpower reduction.
Refractories – Plant Operations, Engineering, Production and Maintenance, Construction of Expansion Project and commissioning, Customer Service and application of specialised refractory materials.
Machinery – Manufacture for Cement, Steel and Tyre Industry – overall In-charge of production unit.
Mining and Equipment – Overall charge of captive Limestone Mines of the Company as various locations, including mines' operations, drilling blasting, transportation and maintenance of Heavy Earth Moving equipment. Preparation of Mining Plans and Environment Control and management.
Industrial Relations – Overall charge of Personnel, IR and HRD matters, with the concerned Mangers reporting to me.
Liaison – Regular liaison with Central and State Government Officials and agencies, local Government administration, Director of Mines, Director of Factories, Electrical Safety Inspectorate, Railways, Electricity supply agencies, etc.

Purchase & Commercial - Overall charge of the Purchase and commercial functions at the New Delhi office of the Company. Identified potential suppliers, rate contracts for Conveyor Belting, V-belts, Electric Cables and Hardware at competitive rates for timely deliveries to various factories of the Company. Negotiations of rates with suppliers, contractors and transporters.

Other Capabilities

I am an excellent Man-manager and have very good leadership qualities. My dealings are transparent and I am "firm and fair". Practically throughout my career, I have worked in a very difficult industry and have shown remarkable performance and results, despite a difficult and even hostile environment, on some occasions.

My training in Industrial Engineering and the experience in this area has stood me in good stead, in identifying and analysing problems and finding/ implementing workable and cost-effective solutions.

Education

# B.E (Electrical) from BITS, PILANI in 1967 in 1st Division.
# Training in Industrial Engineering/ Work-Study from NITIE, Mumbai
# Higher Secondary (school final) from Air Force Central School, New Delhi. Stood 4th in the Board (CBSE). Awarded Certificate of Merit, in lieu of scholarship, by Min. of Education, Govt. of India.
# Primary school education for 3 years was in West Germany, at the American School on the Rhein, when my father was posted at the Indian Embassy in Bonn.
General

# Keen sportsman at school and college. Represented school in Hockey, Soccer and Softball.
# School Prefect and House Prefect at school.
# Lead roles in plays in Hindi and English at school.
# Elected – Class Representative – in Students' Union at College.
# Appointed Secretary of English Language Seminars at College.
# Knowledge of the German language and a bit of French.
# Good knowledge of Computers. I have my own PC.

Date of Birth: 28 February, 1945.
Health: Excellent. Active and Energetic – physically & mentally.

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