Plant Manager

From

A.BALASUBRAMANIAM

Deputy General Manager

Bhilai Steel Plant, Steel Authority of India, INDIA. *********@*****.***, +91-940*******, 799-***-****

RESUME:

Passionate about Mechanical Design, Rolling Mill Management & Water Management.Trained and certified in AutoCAD PTC-Creo parametric & Sheet metal.

Trained and Certified in ANSYS-CFD Fluent and CFX and ICEM CFD HEXA meshing software Organized and trustworthy professional with 33+ years hands-on experience, managing projects, meeting deadlines, expertise in Operation, Production, Quality & Maintenance of Equipments, Reducers, Gear Boxes, globoid & worm reducers, pneumatic & Hydraulic cylinders, pinion stands, housing-less stand roll bearings, pumps, valves, Duplex filters, plate Heat exchangers, Cooling Tower Fans, Rotary Screens, Softeners, Gas and water pipe lines (Diameter upto 1200mm), Compensators, Cooling & Lubrication system, Pressure vessels like Pressure Filters, Accumulators,De-Areators of Water Management Deptt. & Hot Steel Rolling Mills of Integrated, Steel Plant, Condition Monitoring system (CMS), NDT testing, Hydrostatic pressure testing, Erection & Commissioning of pump Houses, WTP, ETP, Closed Cycle water recirculation systems, Housing-less stands, New Bar & Rod Mill Thermo Mechanical Treatment water Quenching systems, Trained and Certified in Rolling Mill Management (CORUS UK), Harvard Manage Mentor training, Cost Control, Six Sigma-green belt pl, TPM, 5S, SAP-ERP PM-Module, Required Knowledge about process and intricacies of Hot & Cold Strip Rolling,Aluminium Pressure Die Casting technology, Acquiring knowledge and skill in AutoCAD & CATIA V5-Design and Wind Energy Technology & Wind Turbines

Executive Profile

* Experienced professional with 18 years of experience in 5.0MT Integrated Steel Plant Water Management Systems, Operate & Maintain Plant Water Management System which consists of Industrial Recalculating Water System (Qty- 1,000,000 M3/Hr), Drinking water system (Qty-2000 M3/Hr ) for plant and Bhilai-township, Water Treatment Plant (Qty-1500 M3/Hr) supplies Soft water for Converter-hood cooling, mould cooling & secondary cooling of Continuous Casting Shop, Demineralised water for Blast Furnace, De-aerated Water for evaporative cooling system of walking beam furnaces of Plate mill, RO water Plant(100 M3.Hr) for Ladle Furnaces Circuit, Effluent Treatment Plant (Capacity-2500 M3/Hr) for Gas Cleaning Plants of Blast Furnace & SMS-Converter, Sewage Treatment Plant(Capacity 800 M3/Hr) for plant and Township. Testing and Commissioning of Water treatment Plants and Effluent Treatment Plants, Maintenance of around 200 Km of Working Water Pipeline Network (diameter up to 1200 mm) inside the pump houses as well as in underground tunnels spreed all over the plant.

* Another 15 years of experience in Hot Rolling Mills with specialization in TMT Bar Rolling, brought improvements in process quality, enhanced equipment availability & performance and increased plant productivity & profitability along with 5 years experience as Project Leader of New Bar & Rod Mill at Bhilai Steel Plant, Steel Authority of India.

* Skilled in taking stringent quality measures including preparation / maintenance of necessary documents to ensure compliance with standards. Integrated Management System & customer requirements. Complied to Integrated Management System, ISO 9001, ISO 14001, OHSAS- 18001, ISO 8000 etc, and SAP- ERP-PM Module.

* Success in strategizing and leading the unit at brink of change and growth.

* Proficient in deploying various methodologies to analyze processes, recommending modifications to minimize escalations, reduce rejection, realize operational efficiencies, control variability, costs & reduce cycle-time.

* Excelled in developing maintenance and operations procedures to increase the efficiency; implementing standards and ensuring adherence to quality standards.

* Overseeing project activities from conceptualization to execution including finalization of technical specifications, procurement / supply of raw materials, stage inspections, scheduling, progress monitoring, site management and managing Contractors & manpower planning., Erection, Testing and successful Commissioning of Unit.

* Skilled in identifying new business opportunities and managing functions

* Versatile, high-energy professional, successful in achieving business growth objectives within turnaround & rapid changing environment with excellent communication, people management, analytical and problem solving skills

Education & Credentials

* Bachelor of Engineering in Mechanical (Ist Class) in 1983 from AC College of Engineering & Technology, Madurai Kamaraj University, Tamil Nadu, INDIA, Awards

*Shop Level APEX Awards

*MD's Innovative Manager Award (3 years consecutively)

*Plant highest Award-Jawahar Award

Key Impact Areas

Employee and plant Equipment Safety

Plant Operations / Production management

Unit Operations

Operations and Maintenance

Team Building & Leadership

Employee Development &Training

Enhanced Quality Production.

Customer Focus

Change Management

Strategic Thinking & Planning

Planning & Procurement

Vendor Management/ Negotiation

Cost Control Management

Project Management

Key Skills

Innovator

Motivator

Communicator

Analytical

Achiever

Divisions Worked With

*Water Management Department-18 years (from 1984 to 1998 and from 2014 to 2017)

*Wire Rod MILL & Merchant MILL -15 years (from 1999 to 2013)

*Bar & Rod Mill - Project Leader-5 years (from 2009 to 2013) Major Achievement:

*Erection and Commissioning of Water Treatment Plant-4 (Capacity-850 M3/Hr) supplies Soft Water to Secondary Cooling System of Continuous Casting Machines.

*Erection and Commissioning of Effluent Treatment Plant-2 (Capacity-1500 M3/Hr) for Gas Cleaning Plant of SMS-II Cunverters.

*Erection and Commissioning of Circulating Water Pump House along with Cooling Towers (Capacity- 3000 M3/Hr) to Qxygen Plant-II.

*Erection and Commissioning of State of Art Technology –Housing-less Stands of Hot Steel Rolling Mill.

*Implementation of Six Sigma, TPM, 5S, SAP-ERP in Rolling Mill & improved Earning of Company by Rs, 120 Cr every year from 2012 .

*Project Leader for 5 years in new Bar and Rod Mill Project. Professional Experience

Since 1984 working at Bhilai Steel Plant, Steel Authority of India Ltd, presently as Deputy General Manager from 2010, worked for 18 years in Plant Water Management Department and 15 years at Rolling Mills.

Key Result Areas:

* Coordinating plant operations for strategic utilization & deployment of available resources to achieve organizational objectives. Managing all technical & managerial aspects, developing reports on performance analysis and handling planning for better productivity. Plant Water Management Deptt.:( Bhilai integrated Steel Plant –Steel Authority of India Ltd.)

* The annual requirement of water for BSP is 110 MM3 (3.8 TMC). This includes drinking water for plant & Township (60 %) and industrial make-up water (40%).

*Operate & Maintain Plant Water Management System which consists of Industrial Recalculating Water System (Qty- 1,000,000 M3/Hr), Drinking water system (Qty-2000 M3/Hr ) for plant and Bhilai- township, Water Treatment Plant (Qty-1500 M3/Hr) supplies Soft water for Converter-hood cooling, mould cooling & secondary cooling of Continuous Casting Shop, Demineralised water for Blast Furnace, De-aerated Water for evaporative cooling system of walking beam furnaces of Plate mill, RO water Plant(100 M3.Hr) for Ladle Furnaces Circuit, Effluent Treatment Plant (Capacity-2500 M3/Hr) for Gas Cleaning Plants of Blast Furnace & SMS-Converter, Sewage Treatment Plant(Capacity 800 M3/Hr) for plant and Township.

* Operate & Maintain Pump Houses - 70 Nos., Cooling towers - 85 Nos, Radial Settling Tanks - 22 Nos, Horizontal Settling tanks - 96 Nos, Filter Houses - 02 Nos, Oxidation Ponds - 04 Nos, Water Chemical Treatment Plant - 02 Nos, Chlorine Stations - 03 Nos, Over Head Tanks - 12 Nos, Ash Pond - 01 No, Testing Laboratory - 03 Nos, Rotary Screens - 10 Nos, Fire Hydrants - 270 Nos at various location of the plant,

*Operate and maintain the TMT Bar-Rapid Water Quenching System of Rolling Mill (to achieve required TMT properties), Roll cooling, equipment cooling, Furnace cooling, Gas Cleaning Plant Scrubbers & Slag Granulation Plants operations.

*Operation & Maintenance of horizontal split casing pumps, Back pullout End suction pumps, Multistage high pressure pumps, vertical axial flow pumps, submersible pumps, slurry pumps with Ni- hard impellers and volute casing, gear pumps, screw pumps, reciprocating pumps, axial flow variable displacement pumps, Cooling Towers, CT Fans, AVGFs, gate valves, butterfly valves, knife edge valves, globe valves, Non Return valves, flocculaters, girder mechanism of Clarifiers/Radial settling Tanks/Thickeners, plate heat exchangers, duplex filters, pressure filters, Accumulators, Pressure Vessels Anion & Cation Exchange Resin Exchangers. etc. Industrial Hydraulic Systems, Project Leader for erection and commissioning of Water Treatment Plant and Effluent Treatment Plant

*Conversant with usage of chemicals like Liquid Chlorine, Alum, Poly Electrolytes, Corrosion Inhibitors, Biocide, caustic Soda, Anion & Cation Exchange Resin, HCL, H2SO4 etc.

*Training of Non-executives & Executives and inculcating the culture of autonomous, proactive maintenance, Running Maintenance, Scheduling and carrying out Capital Repair of Critical equipments though out the year to maintain optimum availability of eqpts for uninterrupted working of process units.

*Drawing development, Planning & Procurement of spares, in-house manufacturing of spares from plant Engineering Shops, cost and inventory control, Material Management, Vendor development to minimise expenditure and improve profit margin.

*As a project leader for the project of Effluent Treatment Plant & Water Treatment Plants study, refine and complete the feasibility Report and move the case for management clearance and after getting management approval, initiation of project, formation of project management committees like Technical Screening Committee etc. for review and recommendations at various levels, discussion with all related technical teams and stake holders in coordination with Consultant, fixing the Eligibility Criteria, work break down schedule for implementation and to facilitate milestone payments, finalise the Technical Specifications (TS) of Mechanical, Electrical & Automation, Instrumentation, Air Conditioning & Ventilation, Illumination, Fire Protection, Chemical Dosing, material Handling mechanisms etc. and also Commercial terms for Tender specifications of the Contract for Installation of Water Pumping Station /Water Treatment Plant /Effluent Treatment Plant in line with the plant requirements and time line, NIT / Tendering, Receiving of offers from bidders, Technical Scrutiny and finalization of supplier of plant, Awarding of Contract, receipt of equipments & Materials in time, strictly adhering all safety procedures with the target of Zero Accident, Coordination with Soil testing, project Civil Foundations and Structural Construction jobs, Erection of plant considering “No Time / Money Over-Run” in line with Contract terms and Conditions, daily regular project review meetings regarding the safety at site, progress of the work with Contractor, concerned agencies and stake holders for required coordination, synchronization, Resource Adequacy, Risk Analysis, Cost Implications if any, for any changes in sequence of work flow and required corrections /rectifications to facilitate job execution within the Timeline as per Contract terms and Conditions, Pre Commissioning Test of plant equipments, fault rectifications for sooth and successful Commissioning, then Commissioning of plant and performance guarantee tests as per Contract terms and Conditions and running of the plant, defect elimination if any through Contractor within guarantee period and stabilization of plant for continuous operation / working. Then give clearance to management for final payment to contractor and closing of the project.

*Ensure safety of working personal & following of safe working practices which is prerequisite for every system.

*Operation and Maintenance of Drinking water and fire fighting pump houses, WTP, STP of BHILAI Township (of population 500,000) and 5.0 MT integrated steel plant.

*Responsible for & Co-ordinate with State Irrigation Board authorities for procurement and periodical release of river water to plant reservoir as per annual agreement and water bill payment.

*”ZERO Liquid Discharge” from Outlets of Steel Plant maintained as per Govt. Norms by implementing water conservation program by monitoring and controlling water flow at various process water inlet points to stop water wastage and also by installing, operating and maintaining recycling PH (and necessary water treatment to maintain quality norms) at various process return water outlets and pumped back into plant re-circulating system and reused.

*Conducted “Water Audit” by CII-Tirveni water Institution to reaffirm “maintaining of stipulated norms” and for further improvements.

* NDT & Hydrostatic Pressure Testing of Water Pipe Lines: NDT-Ultrasonic Thickness Measurement of Working Water Pipeline Network ( varying from dia 300 mm to 1200 mm) inside the pump houses as well as in underground tunnels spread all over the plant and repaired / replaced as per requirement and Hydrostatic Pressure Testing of Water Pipe Lines, Valves, Pressure Vessels are done ad per requirement.

*Risk/Hazards Assessment at Work Environment and preparation of “Emergency Preparedness Plan” and “Mock Drill” conducted involving concerned stake holders(Example: Liquid Chlorine Tunner Leakage).

*Contracts operated regularly for Running Maintenance on working equipments at various pump houses.

*Outsourcing of maintenance jobs done through reputed Contract farms to carry out regular and breakdown maintenance at cluster of pump houses.

* Complied to Integrated Management System, ISO 9001, ISO 14001, OHSAS- 18001, ISO 8000 etc., and SAP- ERP-PM Module.

* worked as Unit Head / Head of the Department and exercised the power and responsibilities of prescribed authority and factory Manager.

Merchant Mill & Wire Rod Mill:

* Managing TMT bar & rod rolling in closed tolerance with optimisation of mill availability and Mill Utilization with adherence to predictive, pro active maintenance by adopting planned Roll change

/Pass Change / planned Mill Repair applying team work dynamics.

*Through Co-Ordination and synchronization activities of Input Billet feed Mill, walking beam furnace, Mill Proper, housing-less stands, TC rings, roll cassettes, rolling blocks, water quenching system, bar and rod finishing station / cooling bed equipment, management of roll turning shop & ring grinding / notching shop, roll assembly / preparation units, Cooling Bed and Finishing Line Equipments, minimisation of Scrap generation, packeting and stacking of finished product bundles, order despatch etc to achieve enhanced production targets / Organisational goals.

* Ensuring co-ordination, facilitation and synchronization with other units related to own area of responsibility (to realize work beyond boundaries) as per management requirement

* Implementation of Corrective And Preventive Action (CAPA) using 5 Why Analysis in Product Quality as well as Plant Maintenance -PM Module of SAP-Enterprise Resource Processing(ERP) on regular basis to improve and optimize rolling Mill equipment performance to improve quality of product and enhance productivity of Rolling Mill.

* Enhancing mill as well as plant performance by adopting and implementing 5S strategy in shop floor/rolling mill and conduction of periodical audits and corrections/rectifications.

* Maintaining and improving the integrity of production and quality systems by ascertaining implementation of TPM in Rolling Mills to implement Autonomous Maintenance to improve Equipment Life so as to bring in process quality improvement and correctness as per customer and market demand.

* Had been Cost (Control) Management I/c for Wire Rod Mill for 3 years and taken following initiatives:

* Inventory Control and Reduction in Consumption of AP hardware and consumable items of stores, Bearings, lubricants etc. by adopting scheduled daily running maintenance and weekly maintenance and immediate defect elimination & corrective actions.

* Development of manufacturing Drawings / finalization of technical specification for mechanical spares so as to procure the same through Limited Tender path at reasonable price instead of purchasing them at very high price on proprietary basis.

* Introduction and implementation of proactive maintenance system to eliminate problem aggravation, to curb sudden breakdowns and minor problems in equipment which disturbs running mill dynamics from reheating furnace to finishing line which thus affects mill utilization, productivity and time line of completion of specific profile rolling schedule and subsequently reduces profit margin.

* Imparting training to work force / maintenance teams by making them aware of the importance of their understanding and involvement in doing quality job on equipment for reliability & sustainability to achieve organizational goals etc.

*Regular frequent meetings and brain storming sessions to improve work culture, employee involvement, equipment health, product quality and productivity to achieve Organisational Goals.

* Managing Total Plant Water Management Systems& maintaining of Rapid Water Quenching System of Rolling Mill (to achieve required TMT properties) which has inherent importance for enhanced Quality Rolling and Productivity of Rolling Mill

* Sourcing stores and spares for Rolling mills and Water Management Systems.

* Complied to Integrated Management System, ISO 9001, ISO 14001, OHSAS- 18001, ISO 8000 etc., and SAP- ERP-PM Module, Operated Contracts for Maintenance on regular basis.

* Encountered many challenges at various positions / levels of my Working like Operation I/C, Maintenance I/C and embraced them with enthusiasm and strived and achieved the Organization goals

Awards

* Project-1: Recognized with the various Shop Level APEX Awards and Received Prestigious Jawahar Award 2000 - repairs and modifications done in cooling bed of merchant mill to minimize the yearly delays from 113 hours to 12 hours

* Project-2: MD'S Innovative Manager Award-2008-09, Re-Installation of Abandoned Water Re-circulating System for TMT Rapid Water Quenching System with Modified Design Pumps & Cooling Tower at Hot Rolling Mills.

* Project-3: MD'S Innovative Manager Award-2009-10. Modifications Done in MILL-Chain Transfer-1 and Allied Equipment to Facilitate to handle Longer Rolled Bar by using Higher Cross Section Input Billets for Profile Angle-50, 65 & Channel-75

* Project-4: MD'S Innovative Manager Award-2010-11 Modifications Done in Cooling Bed & Rope Transfer of Merchant MILL to handle longer rolled bars( with optimised size billet with staggered charging to regulate Reheating Furnace Working Condition) enhance production) in Development and Production of New Product TMT-25 Bars at Bhilai Steel Plant.

* Bagged prestigious MD's Innovative Manager Trophy Award, three years consecutively in 2008-09, 2009-10 & 2010-11 for improving mill productivity by doing i) Re-establishment of Re-cycling Water Circulating System for TMT Bar Quenching System for Design, procurement Equipment s in-house, Erection and commissioning of New Pump House and Cooling Tower.

ii) Modifications doneat Chain Transfer-1 to facilitate to handle longer rolled bar ( by using higher cross section input billet in profiles angle 50, 65, Channel-75 . iii) Modification done in Equipments of Cooling Bed and Finishing rolling line to handle longer length TMT bar using enhanced length Billets to produce new profile TMT25 at Merchant Mill has facilitated in achieving yearly earnings of more than Rs. 120 Crores from 2012 (Recurring) every year to Bhilai Steel Plant. Projects :

*Erection and Commissioning of Water Treatment Plant-4 (Capacity-850 M3/Hr) supplies Soft Water to Secondary Cooling System of Continuous Casting Machines.(1995-96)

*Erection and Commissioning of Effluent Treatment Plant-2 (Capacity-1500 M3/Hr) for Gas Cleaning Plant of SMS-II Cunverters. (1996-97)

*Erection and Commissioning of Circulating Water Pump House along with Cooling Towers (Capacity- 3000 M3/Hr) to Qxygen Plant-II. (1997-98)

*Erection and Commissioning of State of Art Technology –Housing-less Stands of Hot Steel Rolling Mill.(2004-2005)

*Installation of Billet staggering Device before Roughing Stand-1 and Installation of Eccentric Roller Mechanism at feeding point of Cold Shear to improve Rolling Rate thus to improve Mill Productivity.

.(2004-2005)

* Improvements done in Production Quality and Productivity of Wire Rod Mill and as Sr. Project Leader conceiving the project, using TPM, Six Sigma, 5S, ERP and also applying the Management Techniques.(2006-2007)

* Above Management Skill have been acquired from SAIL level- Harvard Manage Mentor Business Management programme by involving and coordinating with Top Management, Project Leaders, Executives & Non-Executives of Operation, Mechanical & Electrical and Automation Section in studying, understanding, gathering & analyzing delay & various other data from system history of Reheating Furnace, Mill proper, Finishing Line Equipment, screening & identifying major contributors affecting product quality, mill availability & mill utilization and mill equipment condition and required corrective actions taken and modifications done.

* Project no: 2, 3 & 4 has facilitated Recurring yearly earnings of more than Rs. 120 Crores from 2012 to Bhilai Steel Plant.

* Six Sigma Project- improve the reduction in % age of arising / scrap in TMT 32 production from 3.6% to 1.08%

Trainings

* Six-Sigma-Green Belt- Project-Merchant Mill input billet length optimization at Billet Mill to increase productivity of TMT bars at Merchant Mill (Long Product Structural Mill).

* Undergone Various Management Training programme at plant Level and SAIL- Management Training Institute, Ranchi.

* Harvard Mentor-manage programme From Harvard Business Management Institution on Strategic Thinking, Change Management, Developing Employees, Innovation and Creativity, Leading and Motivating, Time Management, Delegation, Goal setting, Customer focus etc. Training programme lists are enclosed herewith for reference please

* Undergone Total Productive Management (TPM) system training program to maintain and improve the integrity of production and quality systems through the machines, equipment, processes, and employees that add business value to Organization.

* Got Trained and implemented "5S" at Shop Floor of Rolling Mills.

* Sail-Level "Rolling Mill Management Training Programme" at Corus Steel Plant, Scunthorpe, United Kingdom in 2004.

* Enterprise Resource Processing Training Programme- Implementation of Plant Maintenance module, CAPA-5 why analysis for fault identification and time bound rectification for improvement in eqpt health, Operation of various type of Contracts, to maintain issue of spares and keep track & record of various category of equipment at Hot Rolling Mills.

* Certified Trainee in "Aluminium Die Casting Technology" by Aluminium Casters Association of India

(ALUCAST)_INDIA and North American Die Casting Association (NADCA)] Knowledge Purview:

* Trained and Certified in “Rolling Mill Management” at CORUS Steel Plant, Scunthorbe, United Kingdom in 2004.

* Hot Strip Mill -Walking beam furnace, effect of skid marks in discharged slab and in Hot Strip Mill- de-scalar for surface quality, slab sizing edger, complexity of Nb Micro-alloying, Phase transformation dynamics.

* Strain accumulation in stock (work hardening of metal for toughness) during deformation in stands, rolling stock forward/backward slip with respect to work roll and its effect on inter stand strip differential tension lopper, HSLA Hot strip Rolling & mill dynamics like mill speed.

* Mill modulus/stretch, role of friction coefficient during roll bit/engagement of metal stock during deformation and it's effect on stand load.

* Transfer bar coiling in coil box to restrict temperature loss and to maintain temp homogeneity, achieve stand exit thickness precision using gauge meter & feed-forward method,,HAGC, Rolling of metal in mill stands, laminar cooling of coils, coilers etc.

* Mill process requirement, in Mill automation for mill stability (if it is required to resolve response time delay in network transmission), have understanding of addition of required prediction model with Hydraulic AGC process to get feedback signal in advance so as to offset the original system delay to achieve whole closed loop system, without time delay

* Pressure Die Casting Technology: Trained & Certified in “DIE COSTING TECHNOLOGY-Process Control” by North American Die Casting Association (NADCA) & ALUCAST.

*Gaining experience in Pressure Die Casting, defect Analysis & Quality improvement Conversant with PDC,,PPAP, FMEA, Supplier assessment,

*Expertise in production TOYO, ZITAI machines, Defect elimination and Quality improvement in Al Die Casting. continuous monitoring to optimise M/c Availability and implementation of autonomous, predictive Maintenance practices to improve equipment life.

* Wind Energy Technology : Have clear understanding of Wind Energy Technology and its need and Growth potential in INDIA during the Coming years. I’m actively studying and understanding Wind Turbine Nacelle, Hub, Blades, Pitch Gears and its Bearings for their Criticality, importance of Correct and Proper Lubrication, Predictive Proactive maintenance for the Stability and Sustainability, Light weight Carbon Fibre larger diameter blades, Yaw Gears, Condition Monitoring Systems, Wind Turbine Assembly / Cooling and Conditioning Systems / Maintenance and Service Jobs etc.

*CAD & CAM: Acquiring Knoledge and skill in AutoCAD &CATIA-V5 Design, generation of Tool Path and CNC G-Code & N-Code.

I am self-motivated, dynamic, dedicated, target oriented, sincere, honest and trust worthy, ready to accept any challenge/ responsibility with full energy & enthusiasm to achieve organisational goals.

NOTE: Scan copy of my Credentials are attached herewith for your reference please. Kindly oblige and do the needful please. Awaiting Positive response. With Best Regards,

A.BALASUBRAMANIAM

Deputy General Manager

Bhilai Steel Plant, Steel Authority of India,

*********@*****.***,+91-940*******, +91-799*******

Contact this candidate