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Manager Project/Operation

Best in Industry
January 31, 2018

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Mobile: +**-974*******


Skype: babukobu

Intend to build a career in a leading corporate with experienced people, which will help me to explore myself fully and realize my potential and contribute to the organization which I intend to serve.


A growth-oriented and highly talented Mechanical Engineer with a strong background in product development, design, quality system implementation, meeting customer needs and liaison with customers, Continuous Process Improvement for cost reduction by innovative process improvements, root-cause analysis and experience in leading team members. I have 31 years of rich experience in which 21 years in the field of hot-dip cold rolled coil continuous (annealing furnace & wet flux line) lines, structure galvanizing and wire drawing & wire product lines viz. roofing nails, wire mesh & BRC, barbed wire, chain link, etc. and Pressure cooker, Non stick & Enamel cookware utensils; 3 years in petrochemical field and 7 years in the field of solvent extraction of vegetable oil from oil seeds as well as excellent communication and leadership skills.

At present working as a Consultant, handling Project execution/Operation; Plant start-up & Handover; Conducting Plant performance studies, Safety & Energy audits; Preparing for ISO audits; Third party Inspection, etc; Engaged in a project with M/s. Inframat Alloys Pvt. Ltd., Hosur, Tamil Nadu, India, manufactures – galvanized coils; round, square, rectangular G.I. pipes; structures for galvanizing used for roofing, fencing, shed fabrication, telecommunication tower, solar panel mounting fittings, etc.

An experienced team leader with the ability to initiate/manage cross-functional teams and multi-disciplinary projects, and to deliver cost reduction using VA/VE concepts and process improvements.

Analytical thinking, decision making and problem solving skills and strong innovative experience.

Proficiency in managing projects, execution & commissioning, operation & maintenance of machines & equipment’s with proven abilities in reducing downtime & cost, enhancing operational efficiencies and contribute to achieve the business plan.

Executing cost saving measures to achieve substantial reduction in terms of equipments, manpower and machine utilization. Knowledge on conducting third party inspection and ISO & safety audits.

Strategic planning, execution, organizing with demonstrated Steel Product Development.

Effective communicator & team leader with strong analytical, problem solving & continuous learning attitude. Quick & prompt in decision-making during site executions.

Maintaining the equipment in healthy condition by using the Condition Monitoring & Analysis techniques like Vibration Analysis and Balancing.

Day to day operational and Maintenance activity & long term planning & scheduling, co-ordination and implementation, Budget preparation, Manpower deployment, Close loop monitoring of work progress, criticality and delay analysis, Review of daily activity etc.

Inventory control, consumable & spares parts management, purchase planning.

Adaptability to different cultures/environment and tolerant under stressed situations.

Effective listening, keen observation skills trained to spot abnormalities in process & product variations and generate creative/effective solutions. Tenacity and honesty & sincerity in all my tasks.

Identifying & organizing training needs of team assistants with effective follow up of assigned tasks.

Expertise in determining company’s mission & strategic direction as conveyed through policies & corporate objectives; successful management of entire operations with focus on top line and bottom-line performance.

Key Result Area In Project:-

Four hot-dip Galvanizing Plant project (BRONX, Australia; ROLLCON, India) viz. M/s. Kenya General Industries Ltd., Mombasa, Kenya; M/s. Tororo Cement Ltd., Tororo, Uganda; M/s. R.D. Roofing & Wire Products Ltd., Dar-Es-Salaam, Tanzania; M/s. Societe Industrielle de Bois et d’Acier, Dakar, Senegal and one TOC/CCL (INCO, SPAIN) plant project (M/s. Tororo Cement Ltd.) successfully executed.

Completed the Erection & Commissioning of HR CTL (HK FURUI, China), Manual CTL for CR & GI Sheets, Wire Drawing & Roofing Nails line, Welded Wire Mesh line & BRC (HK FURUI, China), Barbed Wire, Chain Link, Profiler (HAYES, New Zealand), Barrel Corrugation, Lime Plant.

Completed the project execution of Cold Rolled Coil Annealing Plant, Copper Rolling Mill; Pressure Cooker, Non stick & Enamel Cook Ware plant supplied by M/s. Jonson Appliances.

Completed the project execution of the pilot plant for R&D of NOCIL (National Organic & Chemical Industries Limited).

Conceived and commissioned Rice Bran FFA Stabilizing Plant & Cattle Feed Plant.

Erection and commissioning of EOT Crane, Boiler, Rotating equipment like Compressors, Blowers and Centrifugal Fans make-VENTIOLDE, BOLDROCCHI and various types of Gear Boxes and its drives, Structure, Pressure part, Piping (Hydraulic, Pneumatic, Steam, etc.).

Micro & Macro level Planning of Project team members, their responsibilities, project breakdown, budget, Project implementation within the time and budget of CAT (Committed Activity Target) schedule; Managing quality control according to FQP (Field Quality Plan) and maintaining all safety cause, to avoid any accident in project side.

Developed strong communication system for the completion of the project at desirable levels; on site Inspection and Parameter verification when work under progress like installation procedure, alignment of rotary equipment, structure alignment, welding procedure.

To conduct weekly/monthly review meeting with contractors to related to projects; following payments of like erection according to monthly progress and supply payment.

Handed over all documents, drawings, files, and properly arranged operation & maintenance manuals of the equipments.

Prepared the closing of project accounts, resolved outstanding payments, collected the dues and accounts settled.

Settled the crew involved in the execution of the project.

Conducted plant performance studies and achieved project sponsor satisfaction.

Key Result Area In Operation & Maintenance:-

Address challenges and bottle necks in achieving production targets.

Recruited to realign and lead technical group in managing productivity, quality and product & process development. Designed and implemented performance planning processes and procedures (CGL, CTL, Wire product).

Engineered modernization of wire drawing section with annealing furnace to increase the quality of the wire products as well as wire drawing die life.

Executed product development of diverted weld mesh, for value addition.

Recommended QC support with spectrometer, mechanical testing lab and microstructure studies etc.

Launched annual cost reduction of $100,000 by coordinating with external consultant to support engineering added needs for design, development and repair support (Shearing blade, Nails & Weld Mesh M/c.).

Trained team members to CGL & CTL operations and heat treatment techniques of galvanizing kettle.

Increased galvanizing kettle life by 35% by effective operation and reduction in the by-product (top & bottom dross) formation.

Launched annual cost reduction of $75,000 by reviewing/evaluating the design of furnace and galvanizing kettle.

Reduced annual scrap by $50,000 achieved by improving the quality of product and process standardization.

Reduced error rates on product releases by 15% as result of developing and training team members.

Yield improvement by about 12% achieved; adopted the utilization of furnace flue gas temperature for heating the pre & post treatment sections.

Achieved 5% cost reduction in power consumption by proper planning of operations during peak hours.

Trained unskilled locals and developed policies concerning dignity at work and changed the concept of ‘No Hurry in Africa’ in the establishment (M/s. Tororo Cement Ltd.) by fulfilling committed deliveries.

Conducted O&M review meeting, prepared O&M reports, implemented Safety & 5S Activity; Trained to team members for ISO 14000 & Environment Management Systems.

Increased customer confidence by meeting buyer needs and promptly responding to their queries via email and site visiting thus reduced complaints & indirect costs.

Handled the maintenance of glass lined reactor, chemical cracker, vacuum distillation, blending & hydrogenation vessels, heat exchangers, condensers, agitators, pressure vessels, reciprocating & centrifugal air compressor, automatic oil fired boiler, thermic fluid heater, cooling tower, chilling & effluent treatment plant and fire fighting equipment.

Achieved the operation and maintenance of batch & continuous (De-Smet) Solvent Extraction Plants; Have thorough processing knowledge of rice bran, coconut, sal seed, karanja seed, kusum seed, mauwa seed, castor seed, ground nut, etc; Maintained less than 4% Hexane losses; Developed Neutralization & Bleaching of high FFA content oil.

Developed stabilizing of FFA in rice bran during new season to preserve it for a long time.

Prepared and presented production budget models according to the company guidelines, ensured all operations are within budget, identified variances between actual and budgeted results, reviewed budget requests for approval.

Ensured a coordinated flow of work leading to complete manufacture of the product before the arrival of the date promised for delivery; conducted third party inspection; eliminated waste by JIT production.

Competencies involve:-

- Plant Projects - Plant commissioning - Cost saving initiatives

- Maintenance & Operations - Energy Conservation -Training to Workers

Seminars & Workshops: Participated in Awareness Workshop on Total Quality Management (TQM) conducted by M/s. Visisht Corporate Growth Associates Pvt. Ltd., Hyderabad, India.

Computer Skills: Adept with MS-Word & Excel and Internet.


TORORO CEMENT LTD., TORORO, UGANDA; From July 2012 to September 2015 & From April 2004 to May 2006; Plant Manager (Steel Division); Manufacture cement (OPC & PPC), galvanized & colour coated roofing sheets, wire & nails, wire mesh & BRC, barbed wire, chain link, HR plates.

SOCIETE INDUSTRIELLE DE BOIS ET D’ACIER, DAKAR, SENEGAL; From May 2010 to June 2012; Project Manager; Manufacture galvanized & colour coated coils/roofing sheets, wire & nails, wire mesh & BRC, barbed wire, chain link, HR Sections.

GOOD LUCK STEEL TUBES LTD., GHAZIABAD, U.P., INDIA; From February 2009 to April 2010; Production Manager; A 90% export organization; Manufacture galvanized/black M.S.E.R.W. tubes, cold rolled & galvanized coils/roofing sheets, transmission and communication towers, substation structures, tubular poles.

R. D. ROOFING & WIRE PRODUCTS LTD., DAR-ES-SALAAM, TANZANIA; From October 2006 to January 2009; Production Manager; Manufacture galvanized coils/roofing sheets, wire & nails, wire mesh & BRC, barbed wire, chain link.

KENYA GENERAL IND. LTD., MOMBASA, KENYA; From December 2001 to December 2003; Production Engineer; A BRONX CGL; Manufacture galvanized coils/roofing sheets, wire & nails, wire mesh & BRC, barbed wire, chain link.

VARDHMAN IND. LTD., RAJPURA, PUNJAB, INDIA; From December 2000 to December 2001; Senior Engineer (Production); A Flat Product CGL; Manufacture annealed and un-annealed galvanized coils/roofing sheets.

GANESH FERROZINC IND. PVT. LTD., BIRATNAGAR, NEPAL; From September 1993 to December 1999; Production Manager; A TANISAKA SGL/CGL; Manufacture annealed and un-annealed galvanized coils/roofing sheets; copper wires; Pressure cooker, Non Stick & Enamel Cook Ware.


JAI BHARAT UDYOG, FORBESGANJ, BIHAR, INDIA; From April 1982 to June 1989; Plant In-charge; manufacture Vegetable Oils, Cattle Feed, etc.


M.B.A. (Annamalai University) in 2010.

A.M.I.E. in Mechanical Engineering, Institution of Engineers (India) in 1990.

Professional Membership No.AM 72978/5


Father’s Name

Date of Birth

Passport Number


Languages Known

Family Status


Contact Address

Contact No.

Expected Salary

: Shri T. K. Panicker (Late)

: January 15, 1958

: J 0158121

: Citizen of India

: English, Hindi, Malayalam, Tamil & Telugu

: Married with one son doing his B. Tech. At Amrita University.

: Male.

: Ponnath House, P.O.Vadanamkurussy, Dist. Palakkad, Kerala,India. : Pin-679121.

: +91-974*******

: Best in Industry


I hereby declare that the information furnished above is true to the best of my knowledge.


Place: Signature

(Ayyarthodi Ravindra Nath)

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