Resume - BE(Mech) / DMS, 27 years of exp in the field of Plant Maint Managmt including Sa...

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Resume #57596

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1) Job Objective:
Management position in the areas of Plant Maintenance, Renovation, Projects or Technical.
Alternative: Head of Central Cell for organization having multi location production plants which will reducing plant overhead up to minimum 5 % by implementing innovative ideas.
2) Summary of Skills & Experiences:
1. 27 years of experience in the field of Plant operation, Maintenance Management including Safety compliances, Industrial Relations, Budgetary Planning & Control, Project execution in Polyester Synthetics Plant - CP/POLY, POY, PSF, PTA & continuous process plants.
2. Deft in planning and streamlining maintenance operations resulting in effective productivity and enhanced profitability within planned budgets. Expected reduction up to 6-10% per annum by implementation of continuous cost saving plan & strategy.
3. Successfully initiated, designed and implemented various profitable and cost-saving assignments at Polysindo, Indo Rama, Reliance and Nirlon Synthetics.

3) Overseas Assignments handled:
1. SPC, China: For the Erection and Commissioning of Chemtex and DuPont plant in 1991.
2. Toray Engg, Japan & Teijin Seiki, Korea: To assess FDY pilot & PET plant in 1993.
3. Kohap & Honkook Polyester, Korea: To assess SSP plant supplied by Hosokawa, Japan.
4. Kaiping Polyester, China: To assess running FDY plant supplied by EMS-Inventa in 1993.
5. EMS-Inventa, Switzerland: To assess Reliance PET chips trials at the R&D plant in 1993.
6. DuPont, New York: As Technical Rep for J V project of Meter length package in 1994.
4) Educational Qualifications:
* B.E. (Mech.), VJTI Mumbai - 1979 with Ist. Grade.
* Diploma in Management Studies, Mumbai - 1986.
5) Other Distinctions:
Visited 28 Textile companies in Busto Arsizio, Italy as a team member of the Indian Trade Delegation, organized by the Italian Trade Commission in 1998.
6) Languages:
English, Bengali (Mother tongue), Hindi, Marathi, Bahasa Indonesia.

7) Trainings attended:
* Training of POY and FDY Spg m/c at Barmag, West Germany in 1984.
* Training of POY and FDY Spg m/c at Reiter M/c Works, Switzerland in 1984.
8) Specialized Training Program:
1. 21 days training course Energy Conservation, Management & Energy audit (April '06)
2. Indo Rama Potential Development program to access competency ratings in Sep'01.
3. Reliability Centered Maint Program at N P C in Feb '01.
4. Leadership skill for Technical Professionals in Jul '02.
5. Management & Supervisory Development Program at RIL.
6. SAP/ERP & MMS operation RIL & Indo Rama.
9) Exclusive Experience:
I had set up a workshop- Joy Air Enterprises (Year 1986) at Mumbai. Relevant documentation & statutory requirements were obtained by me. Setup was dissolved due lack of financial support.
10) Organizational Experience: The Career Path:
a) From March '03 to till date - M/s Lokesh Industrial Services:
General Manager - Technical Adviser/Consultant
Role Description:
1. Assistance in technical cum commercial bid to bag M/s INDORAMA material handling contract with annual turnover of Rs. 1.5 Millions.
2. Assistance for business collaboration with foreign OEM to establish showroom cum supporting facilities. To access site, a foreign delegate visited Nagpur.
3. Assistance in techno-commercial BHEL Tender bid for 130 Nos forklifts maint & opert.
4. Central India Co-0rdinator for engineering associates from Mumbai.
5. Preparation of Forklift safety cum training manual.
6. Design & Implementation of Lokesh GROUP web site.
7. Assistance to set up workshop for machining, fabrication, Forklift O/H & Show room.
b) From Jan '03 to Jan '06 - PT Polysindo Eka Perkasa, Indonesia
Expatriate Manager - Mechanical Maintenance & Project activities
Maintenance purview:
1. Four line Poly Plant 900 MTPD producing Chips–500 MTPD & PSF–400 MTPD;
2. Poly plant - John Brown Deutsch Engg.
3. PSF Plant - Fleissner & Eastman technology.
4. Poly, Fiber maint. & Specialty fiber Project/Development jobs.
Chief KRAs are:
1. Controlling department having total strength of 100 staff & technician's.
2. 25 ton/day specialty fiber production successfully commissioned.
3. Review, monitoring and improvising the Maintenance procedures and systems to ensure compliance of ISO9002 & ISO14001 along with Statutory Safety Regulation standards.
4. Inventory, Import Sub, Vendor Development, Budget control & cost reduction measures.
Chief Tasks Handled:
MAINTENANCE SYSTEMS & PROCEDURES DEVELOPED:
1. Review & improvise Maintenance Management systems & procedure.
2. Developed maintenance system for the idle POLY Plant for more then a year.
3. Reduced failure rate resulting in less major production losses.
TROUBLESHOOTING
1. Enhancement of crimper performance
2. Successful repair of the centre burner unit of HTM Bertram heater.
3. Analysis & implementation to improvise break level in fiber spinning.
4. Modification of cable bath to reduce fused fiber.
5. Improvement in Maag pump seal operation resulting in improvement in quality.
6. Assisted in the repair work of the finisher agitator shaft to avoid repetitive failure.
TECHNICAL ENHANCEMENTS:
1. Performance improvement by development of 3.5' crimper for tow baling.
2. Fleissner Crimper replaced with Eastman Crimper, Capacity Increase from 35T to 50T
3. Tow cutter performance improvement by installation of Mark-V cutter in place of Mark-IV.
4. Design of specialty fiber spinning. Crystallizer modification batch to continuous process Cost saving > $ 75,000. (35 yrs old unused Equipment)
5. Improvise in the machine part drawings to enhance quality & life of the spares.
COST REDUCTION MEASURES:
1. Alternate vendor development for chrome plating cost saving $30,000 per annum.
2. Reconditioning of mech. parts cost saving @ $25,000 per annum.
3. Development of steam ejector cost saving $30000 one time
4. Development of magnetic filter – cost saving $ 1200 one time
5. Assisted purchase to procure materials at lower cost – Total cost saving > $ 60,000
6. Local development of agitator shaft with improved design for easy maintenance and also cost saving of $5500 for each shaft.
c) From May'95 to Jan'03 - Indo Rama Synthetics (India) Ltd.
May'95 - Oct'98: Sr. Manager (Mech. Maint.), Nagpur.
Oct'98 - Jan'99: Assist. General Manager (Mech. Maint.), Nagpur.
Jan'99 – Jan 03: Chief Manager (Mech. Maint.), Nagpur.
Maintenance purview:
Three CP plants 660 MTPD (Operating at 824 MTPD) producing POY, PSF & Chips plant maintenance along with Central Engg Services, Mech. W/S Maint. of 47 Forklifts & 2 Hydra.
Chief KRAs are:
1. Heading a department with a total strength of 104 Staff & technicians.
2. Monitoring and improvising the Maintenance procedures and systems.
3. Ensure compliance of ISO9002 and Statutory Safety Regulation standards.
4. Monitoring Engg Cell activities from contract order release to Payment stage & MIS.
5. Assistance & support to the project team for finalization of equipments for POY Expansion.
Chief Tasks Handled:
MAINTENANCE SYSTEMS & PROCEDURES DEVELOPED:
1. Developed the Maintenance Management procedure and systems.
2. Introduced the concept of Job rotation among the engineers & technicians.
3. Reduced failure rate with no major production losses in the plant.
TROUBLESHOOTING
1. Identified a major erection fault in the Take up frame of POY machine.
2. Identified leakage and repaired HTM heaters resulting in saving Rs.7.5 Million.
3. Repaired leakage in Heat Exchanger without shutdown resulting in saving Rs. 0.12 Million.
4. Handled Loop Seal welding and Thermo well leakage online to avoid loss of Rs. 5 Million.
5. Rs.5 Million losses avoided by uninterrupted operations despite un-operative Vispac seal.
6. Transfer line GL coupling Dow leakage attended online & avoided shutdown of the plant.
7. Reconditioned mech. seals and saved Rs. 0.9 Millions.
TECHNICAL ENHANCEMENTS:
1. Saved costs up to Rs. 10.5 Million by designing Delay quenches for POY.
2. Saved Rs. 2.3 Million by initiating Plasma Coating for retrieving Rollers.
3. Modified UFPP bubble cap of CP-2 in 4 days vis-à-vis 7 days at DuPont, USA.
4. Saved Rs.12 Millions by fabricating heater top insert in-house based on Bertram's design.
5. Modified the Chipper cutter to 1500 from 1200 kg/hr enhancing 25% revenue.
6. Maag Pump internals replaced saving Rs. 0.25 Million towards technical consultancy fee.
7. Saved Rs. 6 Million by modifying design of POY1 common cutter system similar to POY2/3
COST REDUCTION MEASURES:
1. Spare parts MOC changed saving Rs. 1 Million
2. Saved Rs. 32 Million by analyses & implementing PM Schedule – Winder spindle bearing.
3. Achieved reduction in expenses by Rs.2 Millions through I.E. Study.
4. Cost saving > Rs. 3.5 Million by balancing jobs, Agitator shaft, Motor, Blower & Godet.
5. Cost saving > Rs. 7 Million by Import substitution & alternate vendor development.
6. Achieved cost saving of Rs. 3.9 Million by implementation of suggestion scheme.
STATUTORY COMPLIANCE:
Developed & implemented the ISO documentation & procedures & received No NC.
AWARD RECEIVED (Mech. Dept.):
1. Highest number of suggestion implemented - consecutive three occasions.
2. Highest suggestion (CP, POY, PSF) - 1st Price 2001-02
3. House keeping award - 2001
4. Highest saving achieved by mechanical through CIP (Continuous improvement plan).
5. 100% attendance in fire squad training - consecutive three occasions.
d) From Jul'86 to May'95 - Reliance Industries Ltd, Mumbai.
Joined as Sr. Engineer (Mech. Maint.) and promoted as Superintendent in Oct'89 and later as Additional Manager in Sep'93.
Maintenance purview:
3 CP plants of 60 MTPD, 1 CP plant of 90 MTPD, 17 spinning machines & TEG plant.
Chief Tasks Handled:
1. Technical Team member for the selection of FDY and Bottle Grade PET Projects.
2. Successfully supervised the job distribution of 500 workers & 60 technicians (Day shift), 300 workers and 30 technicians (Night Shift) and department operations for 20 days (20 hrs/day) during '89 flood, which submerge all the equipment below 6' under water. During the period, 100% equipment overhauled with out any damage.
3. Renovated / commissioned 3 old Untrop SDY M/c, DuPont team had failed to commission.
4. SDY m/cs were converted to POY locally. Chemtex team unable to take up the task.
e) From Nov'79 to Jul'86 - Nirlon Synthetics Fibers & Chemicals Ltd, Mumbai.
Joined as Jr. Engineer and promoted as Asstt. Engineer in Sep'84.
Maintenance purview:
CP (VK Tube) for Nylon, Batch Process for Polyester, 6 nos. POY machines of 800m/m, 2 nos. Barmag POY M/cs, 2 Rieter POY M/cs, 2 nos. DCS 1000, 2 nos. SDS8 texturing M/cs, 34 nos. Draw twisting machines, 4 nos. Conning M/cs, Utility boilers, AHU, Generators etc.
Chief Tasks Handled:
1. Successfully relocated and converted the Barmag FDY machine frame to POY.
2. Supervised the entire plant commissioning including the overhauling of 64 nos. Rieter Winders (Second hand) for the POY expansion project.
3. Assembled the Barmag and Rieter HS chuck winder for the Ist. time in Nirlon's history.
4. Deftly handled erection, commissioning & training of Schenk Balancing M/c in RIL/IR/China.

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